2017 VERSION 1

AUSTRAL DECK
technical guide
 AUSTRAL PRECAST Austral Deck TECHNICAL GUIDE

CONTENTS



6.1.1 Strip 2 – Horizontal Span
6.1.3 Check on Column Strip Width
6.1.4 Check on Secondary Moment Direction
6.1.5 Check on Punching Shear
48
Figure 21 – Banded slab deflection profile
48
Figure 22 – Cover requirements for Austral Deck planks
48
Figure 23 – Reinforcement bar laying sequence
49
Figure 24 – Typical internal support splice bar locations
29
30
31
32
build faster, build smarter, build better 7. Fire and Thermal Resistance
Figure 25 – Splice bar calculation of forces 33
Figure 26 – Punching Shear Setback 34
7.1 Fire Resistance Period 51
Figure 27 – Interior Support During Construction 36
7.1.1 Austral Deck Profile 51
Figure 28 – Long term (30 year) deflection for 100%, 44
7.1.2 Thermal Resistance 51
1. Introduction 4.4.3 Negative Reinforcement 32 75% and 50% secondary stiffness
7.1.3 Definitions and References 51
1.1 Austral Deck – Overview 6 4.5 Detailing of Cross Direction Reinforcement 32 Figure 29 – Primary positive moment (about R axis) 45
1.2 Features and Benefits 8 4.6 Calculation of Splice Bars 33 8. Typical Installation Details Figure 30 – Primary negative moment (about R axis) 45
1.3 Applications 9 4.7 Punching Shear 33 8.1 Typical Wall Connection – End Support 52 Figure 31 – Secondary positive moment (about S axis) 45
4.7.1 General Design Issues 33 8.1.1 End Support to External Precast Wall - Option 1 52 Figure 32 – Secondary negative moment (about S axis) 45
2. Properties of Austral Deck
4.7.2 Punching Shear Reinforcement and 33 8.1.2 End Support to External Precast Wall - Option 2 53 Figure 33 – Example Slab 46
2.1 Standard Austral Deck Design Thicknesses, 10
Austral Deck 8.1.3 End Support to Internal Precast Wall 53 Figure 34 – Example Slab 47
Span Table and Graph
4.7.3 Basic Punching Shear Checks 33 8.2 Typical Wall Connection – Longitudinal Side 54 Figure 35 – Austral Deck side profile 51
2.2 Calculation of Austral Deck Weight Reduction 12
4.7.4 Punching Shear Using Rebar Trusses 34 8.2.1 Longitude Side to External Precast Wall 54 Figure 36 – Effective thickness for FRP ccalculation Austral 51
2.2.1 Basic Self-Weight Calculations 12
4.7.5 Alternatives for Punching Shear 34 8.2.2 Side Joint Details 54 Austral Deck profile
2.2.2 Refinements to the Self-Weight 12
4.8 Longitudinal Shear 35 8.3 Typical Wall Connection – Internal Precast Wall and 54 Figure 37 – End Support to External Precast Wall - Option 1 52
2.2.3 Multi-Span Weight Calculation Example 13
Double Wall Figure 38 – End Support to External Precast Wall - Option 2 53
2.2.4 Calculations Using Software 13 5. Austral Deck Design as Formwork
8.3.1 End Support – Internal Precast Wall Under 54 Figure 39 – End Support to Internal Precast Wall 53
2.3 Calculation of Austral Deck Stiffness 15 5.1 Stage one: Design as formwork 36
8.3.2 Mid Span – Internal Precast Wall Above 55 Figure 40 – Longitude Side to External Precast Wall 54
2.3.1 Calculation of the Neutral Axis – 15 5.2 Design Criteria and Specifications 37
8.3.3 End Support – Double Wall Connection 55 Figure 41 – End Support – Internal Precast Wall Under 54
Elastic Section 5.2.1 Strength 37
8.4 Typical Beam Configuration 55 Figure 42 – Mid Span – Internal Precast Wall Above 55
2.3.2 Calculation of the Moment of Inertia 15 5.2.2 Stiffness 37
8.4.1 Beam Reinforcement within Slab Thickness 55 Figure 43 – End Support – Double Wall Connection 55
2.3.3 Calculation of Elastic Stiffness Allowing for 16 5.2.3 Surface Finish 37
8.4.2 Precast Beam 56 Figure 44 – Beam Reinforcement within Slab Thickness 55
Joints 5.2.4 Panel Capacity 37
8.4.3 Band Beam formed by Austral Deck 56 Figure 45 – Precast Beam 56
5.2.5 Maximum Span 37
3. Modelling Austral Deck 8.5 Balcony and Cantilever Arrangement 57
5.2.6 Stacked Materials 38 Figure 46 – Band Beam formed by Austral Deck 56
3.1 Design Principles 17 8.5.1 Balcony and Cantilever Arrangement 57
5.2.7 Assumptions 38 Figure 47 – Balcony and Cantilever Arrangement 57
3.2 General Modelling 17 8.5.2 External Precast Wall with Balcony 57
5.3 Panel Properties 39 Figure 48 – External Precast Wall with Balcony 57
3.2.1 Outputs from Modelling 17 8.6 Proposed Propping Arrangement 58
5.3.1 Construction Loads 39 Figure 49 – Proposed Propping Arrangement 58
3.2.2 Code Compliance 17
5.3.2 Load Combinations 39
3.3 Using Ram Concept 17
5.3.3 Design Load 39 LIST OF FIGURES LIST OF TABLES
3.3.1 Adjustment for Structural Weight 18
5.3.4 Truss Properties 39 Figure 1 – Typical Austral Deck Cross Section 7
3.3.2 Average Slab Thickness 19 Table 1 – Standard Austral Deck Slab Thicknesses 10
5.3.5 Top Chord 39 Figure 2 – Integration with steel framed sructure 8
3.3.3 Reduced Concrete Stiffness 19 and Design Properties
5.3.6 Bottom Chord 39 Figure 3 – Austral Deck Cross Sections 12
3.3.4 Isotropic vs Orthotropic Stiffness 20 Table 2 – Span to Deck ratios for residential application 11
5.3.7 Diagonal Lacing 39 Figure 4 – Plan of Austral Deck Around Column 13
3.3.5 Austral Deck and Orthotropic Stiffness 20 Table 3 – RAM Concept Concrete Mix Properties 18
5.3.8 Mesh 39 Figure 5 – Typical Multiple Span Austral Deck Layout 14
3.3.6 Orthotropic Stiffness and Australia Code Table 4 – Reduced Austral Deck densities for regular 19
5.3.9 Capacity Calculations 40 Figure 6 – Elastic Analysis of Panel Joints 16
Compliance 20 and bathroom slab areas
5.3.10 Top Chord Compression 40 Figure 7 – RAM Concept Menu 18
3.3.7 Austral Deck and RAM Concept Design Strips 21 Table 5 – Design column and interior strips as 20
5.3.11 Top Chord Tension 40 Figure 8 – Slab properties showing Austral Deck 19
3.3.8 RAM Concept and AS3600-2009 21 defined by AS3600-2009 Section 6.1
5.3.12 Bottom Chord Compression 40 concrete mix and custom reduced stiffness
Implementation Table 6 – Typical load history settings for a 22
5.3.13 Bottom Chord Tension 40 Figure 9 – Design strip distribution from 20
3.3.9 Austral Deck and RAM Concept Deflection 21 residential Austral Deck slab
5.4 Panel Properties 39 AS3600-2009 Table 6.9.5.3
Analysis Table 7 – AS3600-2009, Table 4.3 - Concrete 30
5.4.1 Bottom Chord Tension 40 Figure 10 – RAM Concept load history options 21
3.3.10 Example Austral Deck Load History Settings 22 Exposure Classification
5.4.2 Diagonbal Lacing Compression 41 Figure 11 – RAM Concept strip layout example 23
3.4 Austral Deck Design Strip Layout in RAM Concept 23 Table 8 – AS3600-2009 Table 4.10.3.3 - Concrete Cover 30
5.4.3 Concrete Panel Compression 41 Figure 12 – RAM Concept strip layout - 3D render 23
3.4.1 Example Design 23
5.3.4 Control for Concrete Tensile Strength 41 Figure 13 – Example model showing mesh area layouts 24
3.4.2 Flat Plate 24
3.4.3 Banded Slab 28
5.3.5 Crack Control for Flexure 41 Figure 14 – Example plank layout #1 25 LIST OF CHARTS
5.3.6 Deflection 42 Figure 15 – Example plank layout #2 25
4. Austral Deck and AS3600 Detailing Requirements Chart 1 – Span Chart Guide 11
5.3.7 Maximum Scans Summary 42 Figure 16 – Latitude and longitude design strips 26
4.1 Concrete Cover 30 Chart 2 – Maximum distance between supports for 43
5.3.8 Single Span 43 Figure 17 – Longitudinal sections generated from 27
4.1.1 Code Requirements 30 single span
5.3.9 Two Span 43 design strips
4.2 Ductility Requirements in Flexural Reinforcement 31 Chart 3 – Maximum distance between supports for 43
6. Example Models and Calculations Figure 18 – Banded slab layout 28
4.3 Reinforcement Laying Sequence 31 multi span
6.1 Sensitivity Analysis of Two-Way Slabs – Example 1 44 Figure 19 – Banded slab 3D render (viewed from below) 28
4.4 Detailing of Span Direction Reinforcement 32 Chart 4 –Fire Resistance Period 11
6.2 Worked Calculations 46 Figure 20 – Longitude strip layout for banded slab 29
4.4.1 End Supports 32
6.1.1 Strip 1 – Vertical Span 47
4.4.2 Internal Supports 32

/2/ /3/
AUSTRAL PRECAST Austral Deck TECHNICAL GUIDE

AUSTRAL DECK
design for construction, loading,
permanent formwork, span capacity
and final in service slab

The information contained in this document is provided

as a general guide only and does not replace the need for the specification to
be reviewed and checked by a qualified person in the field of concrete,
energy, building construction, sound, design, services and/or fire.

This material has been prepared in the context of relevant

Australian Standards, the National Construction Code (NCC) and the
Building Code of Australia (BCA). Users should make themselves aware of
any recent changes to these documents referred to therein
and to local variations or requirements.

Austral Precast has dedicated engineering services available for project

assistance. We are able to provide design support for engineers to determine
the best way to specify and document Austral Deck.

Our technical experts can identify the most efficient panel geometry meeting
project requirements, specifications and installation process.

Austral Precast offers fully detailed shop drawings as part of the

Austral Deck supply.

It is the client’s designer who is responsible to design and certify the

concrete slab, the entire structure and certify the panel design for temporary
propping and construction loads.

/4/ /5/
 AUSTRAL PRECAST
1. INTRODUCTION
Welcome to Austral Deck, an innovative, cost effective and
time saving precast concrete flooring solution, designed to
provide a one way and two-way spanning concrete floor slab
and formwork solution in one.
Austral Deck combines features developed from many years of
research, development and construction projects to provide a
flexible solution that enables engineers, architects and
builders to understand and use the solution as seamlessly as if
they were designing a traditional concrete framed building.
The Guide aims to enable users to:
• Achieve a preliminary understanding of the Austral Deck
solution, spans, costs and limitations
• Undertake designs and understand the theory behind their
implementation
• Understand the way that Austral Deck is constructed, and
plan accordingly.
/6/
Austral Deck TECHNICAL GUIDE
1.1 Austral Deck – Overview
Austral Deck is based around a small number of key
components, that combine to form a fully bonded, concrete
slab.
The components combine the strengths, savings and benefits
of precast concrete with the flexibility and simplicity of 06 05
traditional in-situ formed, poured and finished floor slabs.
The solution can be broken down into the following key
components (Figure 1):
1. A thin precast concrete “Austral Deck panel” providing a
Class 2 bottom soffit finish whilst serving as formwork.
07
2. Reinforcement bar (rebar) and mesh cast into the Austral
Deck panel, providing concrete spanning capability and
contributes to slab reinforcement. 01
3. Triangular steel lattice girder “trusses” made from welded
rebar, providing temporary stiffness for transport and
03 02
installation. They provide permanent shear flow transfer
04
capability.
4. Void formers, reducing the weight of the overall slab and
Figure 1 – Typical Austral Deck Cross Section
increasing the efficiency of the concrete section.
5. On-site installation of top reinforcement and splice bars, 01 Austral Deck
providing easy access to cast in services whilst achieving 02 Steel reinforcement if specified
03 Steel lattice girder
rapid steel fixing time frames on site.
04  Steel mesh casted in the Austral Deck
6. In-situ poured concrete topping. 05  Void formers
06  In-situ concrete topping
07  Slab thickness
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 AUSTRAL PRECAST
1.2 Features and Benefits
Austral Deck is easy to design with and fast to install, saving
time and money across the construction life cycle.
A flexible and adaptable formwork, Austral Deck integrates
well with Austral Precast walling solutions, covering the
entire structure including cantilevers and balconies.
A unique flooring solution
• A n Austral Deck panel is part of a composite floor solution
that provides rigid formwork that becomes part of the final
structure. During construction the panel can stand
construction loads and be used as a platform for workers and
materials.
• A n effective way to maintain the structural integrity of a
monolithic slab.
• Composite platforms and shear connection panels can be
constructed easily with partial or full-length gaps or pockets
of concrete voids. The gaps will be located to accommodate
structural beam configurations. This allows for the
placement of the Austral Deck directly over precast, cast
in-situ concrete or steel beams. Trusses and steel
reinforcement can remain uninterrupted through these gaps
for structural continuity. – Figure 2.
• This permanent formwork solution has been approved by
many state road authorities, providing safer and more
efficient construction of bridge superstructures.
• The quality of the form Class 2 finish on the under side of the
Austral Deck floor can eliminate the need for a false ceiling,
maximising floor to floor height.
A flexible and adaptable formwork replacement
• Austral Deck imposes minimum restrictions on designers
and builders. Custom made sizes and shapes can be
manufactured to suit construction layout and design
specifications.
• Austral Deck panels can cover the entire width of a
structure, including the cantilever beyond the external
support. Refer to Section 8, Typical Installation Details.
• The solution integrates well with concrete or steel framed
structures. – Figure 2.
/8/
• Cast-in items such as ferrules, conduits and other service
fixings and penetrations can be accommodated during the
manufacture of Austral Deck.
• Balconies and edge forms can be cast within the Austral
Deck panel. These can eliminate edge formwork and scaffold
costs. Integrated edge forms allows for early installation of
temporary or permanent balustrades.
• Safety rail post holes can be prefitted to the panels prior to
installation, improving site safety.
Economic and fast to install
Austral Deck offers all the advantages of a precast concrete
system;
• Reduction in formwork and propping compared to
conventional formwork.
• To further increase efficiency on site, Austral Deck panels
may be produced with void former blocks attached to the top
of the precast. These formers reduce the volume of in-situ
concrete topping volumes and reduce the overall mass of the
floor structure by up to 30%.
• Construction trades can commence working on the structure
immediately after installation. Service ducts and conduits
can be installed and accommodated into the cast in-situ
portion of the slab.
• Austral Deck can be lifted straight into position, reducing
conventional installation time. An average of 10 Austral Deck
panels (covering an area of 150m2) can typically be installed
per hour.
• The panels have a relatively thin layer of concrete, which
makes it lighter to transport and install.
• Austral Deck has the properties to achieve fire resistance and
energy efficiency provisions as specified in relvant standards
and building code of practice. Refer to Section 7 in this guide
"Fire and Thermal Resistance".
Figure 2 – Integration with steel framed structure.
Austral Deck TECHNICAL GUIDE
1.3 Applications
Austral Deck has been designed to be as flexible as possible,
and therefore ideally suited for a broad range of construction
applications.
Some of the applications that Austral Deck is suited for are as
follows:
• Multi-Level Residential Developments, including:
> Exposed flat soffits with quality concrete finish
> Upstands and balconies preformed and/or precast
> Irregular column grids
> Flexibility of loads, penetrations, ducts and set-downs
• Commercial Developments, including:
> Long span floor plates
> Flat slabs, reduce losses in ceiling space for tenant
services and mechanical services reticulation
> High loaded areas such as compactus and storage
zones
> Good interaction and connection with precast concrete
lift and stair cores, shear walls and other features
> Cast-in fittings for curtain walling systems
• Parking and open-deck applications
> Fast construction times allow opening of carparks
sooner, minimising loss of car bays and maximising
economic benefits
> Light weight concrete spans allow for more efficient
structures
> R amps, aisles and traffic movement areas can easily be
accommodated within the Austral Deck design
• Decks and platforms
> Traffic and pedestrian bridges
> Curved on and off ramp structures
> R ail platforms
> Marine jetties and platforms
• Roofs and lids
> Tunnel and shaft roof panels
> Culverts
> Tank lids
/9/
 AUSTRAL PRECAST Austral Deck TECHNICAL GUIDE

2. PROPERTIES OF AUSTRAL DECK

Table 2 shows span to depth ratios for residential application of Austral Deck.
This chapter will detail the structural and geometric properties of Austral Deck.
Upper Span Limit
Total Depth Precast Panel Topping Void Depth
Austral Deck has been designed to be completely flexible with regards to depths, sizes and layouts. The standard designs below Code Single Continuous
mm mm mm mm
allow for a streamlined detailing process, as many of the forms, trusses, chairs and jigs are already available in many of Austral mm mm

Precast’s factories around Australia. AD150 150 60 90 N/A 3500 4500

AD175 175 60 115 N/A 4000 5200

2.1 Standard Austral Deck Design
Thicknesses, Span Table and Graph AD200 200 60 140 50 4500 6000

Table 1 shows various standard thicknesses of Austral Deck. AD225 225 60 165 100 5000 6500

AD250 250 60 190 120 5500 7300

Total Precast Topping Void Theoretical Equivalent Stiffness Equivalent Stiffness
Code Depth Panel
Weight Reduction* (Strong Axis) (Weak Axis) AD275 275 60 215 145 6000 7750

mm mm mm mm mm % mm % mm % AD300 300 90 210 130 6700 8500

AD150 150 60 90 N/A 150 0.0% 150 100% 150 100% AD350 350 90 260 160 7750 10200

AD400 400 90 310 210 8750 11500

AD175 175 60 115 N/A 175 0.0% 175 100% 175 100%

AD200 200 60 140 50 175 12.7% 199 98% 198 98%

Table 2 – Span to Depth ratios for residential application
AD225 225 60 165 100 174 22.6% 221 94% 220 93%

AD250 250 60 190 120 189 24.4% 244 93% 243 91%

AD275 275 60 215 145 201 26.8% 266 90% 264 89%

AD300 300 90 210 130 234 22.0% 294 95% 293 94%

AD350 350 90 260 160 269 23.2% 342 94% 341 93%

AD400 400 90 310 210 293 26.7% 387 90% 384 89%

Table 1 – Standard Austral Deck Design Thicknesses

There are several key assumptions inherent in the standard
design table, which are detailed as follows.
• Generally, the panels are optimised to allow for 60mm or
90mm precast biscuit at the base and minimum 60mm cover
to the top of the polystyrene void former.
• Weight reduction and equivalent stiffness factors are based
on a typical plank, 2500 x 7800mm, with 18 void formers of
size 550 x 1000 each.
• *Theoretical weight reduction ignores any additional void
formers removed around columns and walls, penetrations,
cast-in anchors, transfer beams or other features that
require full thickness concrete.
• Stiffness equivalents are based on elastic section analysis of
the concrete cross section only. Cracked or transformed
section analysis should be carefully undertaken by the
design engineer.

A standard 250mm thick slab has a 23% weight saving of the structure,
with only 7.5% loss of stiffness Chart 1 – Span chart guide

/ 10 / / 11 /
 AUSTRAL PRECAST
Typical Austral Deck dimensions and cross sections are shown in Figure 3.
Figure 3 – Austral Deck Cross Sections
2.2 Calculation of Austral Deck Weight
Reduction
The accurate calculation of the weight reduction is critical to
the design of the structure.
Structural self-weight must be included for all calculations on
slab performance. If the self-weight reduction due to the void
formers is ignored then the slab will become needlessly
conservative both for strength and serviceability calculations.
As a designer, one must also remember that for any concrete
spanning element, serviceability (i.e. stiffness) effects are
multiplied and amplified with the additional effects of creep
and shrinkage. In some cases, this can cause significant over
or under-estimation over the long term life of the project.
Self-weight has flow-on effects to the vertical and lateral
supporting elements of the structure. Whilst the Austral Deck
designer normally would only concern themselves with the
design of the suspended slabs, any material change to the
self-weight of the slabs will have flow-on effects, by increasing
(or decreasing) the columns, foundations and transfer beams
providing vertical support and cores and shear-walls
providing lateral support.
Generally, over-estimating the self-weight of the structure
would provide a conservative design, however for lateral
elements, particularly for tall and slender buildings, the
designer should also be careful as under-estimation of the
building weight would put excessive tensile loads on the lateral
support systems, by not providing enough tie-down force to
counteract overturning effects.
Lastly, and possibly most importantly, if Austral Deck is
adopted on a project after the preliminary and concept designs
have already taken place, the designer should be careful not to
increase the weight of the slabs, causing a flow-on increase in
the costs of all the vertical and lateral elements above.
/ 12 /
2.2.1 Basic Self-Weight Calculations
Calculate self-weight based on an average slab thickness and
average reduction due to the voids.
For example, taking a typical 2.5m x 7.8m plank in a 250mm
thick concrete slab, the concrete volume is:
2.5 × 7.8 × 0.25 = 4.875m3
Over the plank area, there are 18 voids, in 6 rows x 3 columns.
Each void is:
550mm x 1000mm x 120mm, or 0.066m3 per void.
In total the concrete volume for the plank is therefore:
2.5 × 7.8 × 0.25 – 18 x (0.55 × 1 × 0.12) = 3.687m3
The total average reduction in the concrete slab is:
3.687
1– = 24.4%
4.875
From a starting point of a 250mm slab, this is the weight
equivalent of a 189mm slab.
2.2.2. Refinements to the Self-Weight
The basic self-weight calculations take into account the
general proposed layout for a 2.5m x 7.8m plank, including
200mm solid sections longitudinally and 400mm solid plank
ends.
However, there are many more areas where it may not be
possible to achieve the maximum and most efficient void
arrangement.
It is advised that there is a minimum of 500mm clearance
around all load bearing elements and connections on a typical
slab. That includes load bearing columns, walls and cores, as
well as transfers, steps, folds and bathroom setdowns.
In some cases, it may not be feasible or practical to use void
formers at all, usually once the slab depth narrows to under
175mm.
Austral Deck TECHNICAL GUIDE
A typical layout of planks around a square column is shown
below in Figure 4.
The figure shows a 600x600 square concrete column, with the
precast planks stopping short of the column by 20mm all
round.
There is minimum 500mm clearance to the column in one
direction, and 675mm in the orthogonal direction. Note,
675mm allows the voids to remain in line and would not
interfere with the reinforcement or rebar truss layout.
To calculate the effective or average self-weight for this
example, an average should be taken over several column
grids.
Note: the positioning of the 500mm clearance around
columns and other load bearing elements is considered the
minimum to allow for general detailing of the column-slab
joint. It does not consider any punching shear perimeter,
which may require a larger solid region around the column
than depicted in Figure 4. Refer to Section 4.7 for further
details on Punching Shear.
An example calculation is shown opposite in Section 2.2.3.
Figure 4 – Plan of Austral Deck Around Column
/ 13 /
2.2.3. Multi-Span Weight Calculation Example
The basic self-weight calculations take into account the
general proposed layout for a 2.5m x 7.8m plank, including
200mm solid sections longitudinally and 400mm solid plank
ends.
The example shown in Figure 5 shows a slab of 2 x 2 grid bays
of 7.5m x 7.8m each.
The 250mm slab has 9 columns each of 600 x 600.
Using a typical case where the slab beneath a column is
included in the slab volumes the total volume of this slab is:
15 × 15.6 × 0.25 = 58.5m3
Excluding the void free areas around the columns the normal
reduction of 24.4% equates to a total volume of 44.2m3.
However there are a number of smaller 600x550 voids around
the columns. The total void volume:
[16 × 0.4 × 0.55 + ( 12 × 18–16) × 1 × 0.55] × 0.12 = 13.62m2
13.62
Volume Reduction = = 23.2%
58.5
If the slab were to have setdowns, walls and folds, as is likely
for a residential apartment complex, the volume reduction
may well reduce to 20% or beyond.
2.2.4. Calculations Using Software
It is possible to use 3D modelling software to calculate rough
slab volumes and therefore self-weights, including Tekla,
Autodesk Revit or Bentley Microstation.
When using any modelling software, the designer and
draftsperson should always have in mind the additional
complexity of modelling voids, and take care not to use any
volume outputs without hand checking the results.
 AUSTRAL PRECAST Austral Deck TECHNICAL GUIDE

2.3 Calculation of Austral Deck Stiffness 2.3.1. Calculation of the Neutral Axis – Elastic
Section
The elastic stiffness of a suspended slab (or any structural
element) is solely dependent on two properties; The neutral axis of the cross section is found as follows:
Q = ∑ y∙dA
• Material properties, E, the Young’s Modulus
(2.5 × 0.25m) × 0.125 – 3 × (0.55 × 0.12) ×0.120)
=
• Geometric properties, I, the Second Moment of Inertia (2.5 × 0.25m) – 3 × (0.55 × 0.12)

The effective, transformed stiffness of a suspended slab = 127.3mm

depends on a number of non-linear and behavioural

properties of the concrete material and layout within the
structure, including;
• E xtent of cracking, influenced by reinforcement ratio,
concrete material and horizontal prestress as per AS3600
sections 8.5.3 and 9.3
2.3.2. Calculation of the Moment of Inertia
The Moment of Inertia of the cross section is found using the
parallel axis theorem as follows, assuming an elastic,
uncracked section.
Ixx = ∑ y2∙dA

• L oad duration (ψ factors) and Dead to Live Load ratios = bd3

+ Ay2 (Concrete minus voids)
12
• Creep, influenced by environmental conditions, concrete
= 2.5 × 0.253 2
( 0.55 ×120.12 )
3
strength and hypothetical slab thickness as per AS3600 + 2.5 × 0.25 (0.125-0.1273) – 3
12
section 3.1.8
– 3 (0.55 × 0.12) (0.12 - 0.1273)2
• Shrinkage, influenced by environmental conditions,
= 3010 × 106 mm4
concrete strength and hypothetical slab thickness as per
AS3600 section 3.1.7 Without void formers, the Moment of Inertia of the equivalent
section would be:
Generally in the case of Austral Deck slabs, the calculation of
2.5 × 0.253
stiffness is no different, however the designer should also take Ixx = = 3255 × 106 mm4
12
the precast concrete panel joints into consideration. For
example, stiffness across panel joints every 2.5m on a 10m The reduced stiffness in this case is only:
span may well be reduced by 10%, as indicated in section 3010
= 92.47%
2.3.3. 3255

In general, we ignore any changes to the Young’s Modulus of In other words, for a standard 250mm thick slab, there is a
the section, as the concrete is usually a relatively standard 23-24% weight saving of the structure, with only 7.5% loss of
strength mix, with well-known properties. Concrete stiffness.
specification is discussed further in this document.

The geometric stiffness depends on the layout and position of

the void forms and for fully transformed sections, the location
of the reinforcement.

For computer modelling purposes, the voids are considered

using a traditional elastic modulus calculation.

For the example in Section 2.2.3 the stiffness of a plank is

Figure 5 – Typical Multiple Span Austral Deck Layout calculated below:
Note: Refer to 2.1 about Theoretical Weight Reduction. Some voids might be
required to be removed to place the splice bars.

/ 14 / / 15 /
 AUSTRAL PRECAST Austral Deck TECHNICAL GUIDE

2.3.3. Calculation of Elastic Stiffness Allowing

for Joints
It should be noted that the below case is for a solid, elastic
section only, and does not include effects for voids,
3. MODELLING AUSTRAL DECK
transformed sections, creep, shrinkage etc. Only the impact of
The calculation of a reduction of stiffness based on the precast
the panel joints are modelled.
concrete joints can be estimated based on simple linear elastic
calculations, but a detailed finite element model may be more Whilst the joint location may seem trivial, the over impact on 3.1 Design Principles 3.2.1. Outputs from Modelling
useful. deflection may be critical, and the location of joints should be
This chapter primarily discusses the use of computer Just like an ordinary suspended concrete slab, Austral Deck
positioned where possible to produce minimal impact on the
For example, Figure 6 below are two spans, approximating a modelling software to analyse and design Austral Deck in a can be modelled using 1-D (strip run), 2-D (area plan) or 3-D
slab, such as the one-quarter to one-third points of the slab
280mm thick, 1000mm wide concrete slab spanning 10m. The variety of project settings. The chapter mostly uses examples (full building) software.
where a point of inflection exists.
lower span has three joints at 2500mm centres, where the slab and specific settings from RAM Concept, by Bentley Systems, The designer can use the normal software outputs such as load
thickness is reduced by 60mm. however the general principles can be applied to any internally run-downs, bending moments and deflections to design and
The joints are set to be 20mm wide and the slab in the joint is recognised software package, including SAFE/ETabs (by design-check the suspended slab.
raised such that the top of slab remains constant (i.e. elastic Computers and Structures Inc), RAPT (by PCDC), Slabs (by
Inducta), Strand7, SAP2000, DIANA and other Finite Element Some software has also been specifically developed to output
neutral axis is raised by 30mm).
Analysis packages. detailed designs, including strip-run analysis, reinforcement
The deflection for the model below has increased by between design and detailing and even bar bending schedules. Any
1% and 2% overall at the midspan. In general, the design of the Austral Deck consists of two output related to the reinforcement and strip analysis of
design stages Austral Deck should be carefully checked, as some of the
0.000 0.000 0.000.0.000 1st Stage : Design as formwork detailing requirements are different to a normal suspended
0.000 -0.043 0.000 -0.043
reinforced concrete slab.
0.000 -0.079 0.000 -0.102 0.000 -0.110 0.000 -0.102
0.000 -0.079 Must be designed for
3.2.2. Code Compliance
• Lifting during manufacturing
0.000 0.000 0.000 0.000 Austral Deck has been designed such that it is code compliant
• Transport
0.000 -0.043 0.000 -0.079
0.000 -0.043 with all of the standard design and construction codes that
0.000 -0.079 0.000 -0.103 0.000 -0.111 0.000 -0.103
• Lifting during installation exist around the world. These include:
Figure 6 – Elastic Analysis of Panel Joints
• Construction loads during use as formwork • A S3600-2009 – Concrete Structures

2nd Stage: Final in-use slab design • A S3610-1-2010 – Form Work for Concrete

• Must be designed for strength and serviceability for
in-service situation as per conventional reinforcement
concrete suspended slab
• Eurocode 2 – 1992-1-1 - Design of Concrete Structures
(Europe)
• BS8110 – Structural Use of Concrete (United Kingdom, now
superseded by Eurocode 2)

3.2 General Modelling • ACI318 - Building Code Requirements for Structural

The concept and general properties of Austral Deck can be
analysed and designed using regular methods, concepts and
codes that would normally be employed to design a reinforced
concrete suspended slab.
In general, the designer needs to take account of the following
properties and changes:
• Structural mass – changing the concrete material properties
to account for void formers.
• Structural stiffness – changing the slab shape properties to
account for void formers.
Concrete (Nth America)
• NZS-3101 – Concrete Structures Standard (New Zealand)
The designer should make themselves familiar with the
particular code requirements for analysis, design and
detailing for the region that is most relevant to the project.
In addition, the designer should also make themselves
familiar with additional code requirements for materials and
testing of reinforcement, concrete, formwork, temporary
works and propping that is relevant to the project location.

• One vs Two-way spanning – changing the shape properties
to account for non-isotropic properties of the precast joints
and void former shapes.
3.3 Using Ram Concept
RAM Concept (by Bentley Systems) is a two-way analysis
package, using Finite Element Analysis (FEA) to determine
loads and actions for a suspended concrete slab. It can be
customised and can be used to design, check and detail
concrete slabs, including Austral Deck slabs.

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 AUSTRAL PRECAST Austral Deck TECHNICAL GUIDE

RAM Concept can undertake analyses and code compliant
detailing for a variety of country specific concrete standards.
Only relatively minor adjustments are required to enable RAM
Concept to be compatible with Austral Deck, which are
detailed below. It is important to note, however that there are
many other options in RAM Concept that the Austral Deck
designer can be used to adjust or “tweak” the analysis or
design. Designers should always familiarise themselves with
the limitations of the software and undertake sensitivity/
variance analysis runs to ascertain the magnitude of impact
on any of these options.
Note: The following examples are based on current menus and
screenshots from RAM Concept CONNECT Edition,
v6.00.01.006 x64. Other versions may have slightly different
menu configurations.
From the Materials screen, the designer should select a
concrete strength most likely to be used – generally this would
be 32MPa or 40MPa (N32 or N40) grade concrete.
Select “Add Concrete Mix” and name it to appropriately reflect
the Austral Deck mix, e.g.: “50 MPa (Austral Deck).
Copy the concrete mix properties, ensuring that the strength
and stiffness properties remain the same as the ordinary
concrete mix (refer to Table 3).
Reduce the concrete Density by a factor calculated/estimated
to be the slab average, allowing for weight reductions from
void formers.
For example, for a rectangular, regular carpark slab in
Figure 4 the maximum density might be 24.4%, but the
average reduction might be 20%. Conservatively, the designer
3.3.2. Average Slab Thickness It is recommended to reduce only the bending stiffness
coefficients as per Figure 8. For RAM Concept, the coefficients
Designers should also take care when calculating the average
are found in the Slab Properties of the Mesh Input window.
density for highly variable slabs, such as residential slabs with
bathroom and wet-area setdowns, balconies and closely
spaced load bearing elements.
Each of these items would alter the average slab thickness and
density reduction.
The designer should always err on the conservative side of
judgement when calculating average weight reductions. For
the example shown in Figure 2 3, a residential slab may have a
reduction of 10-12%, with an equivalent density of 2112 –
2160kg/m3.
For large floor areas, it is also possible to add multiple slab
types with multiple densities, as per Table 4.

3.3.1. Adjustment for Structural Weight may even use 17% as an initial assumption.
Density Density For f 'ci f 'c
MIX NAME
On creating a new “Elevated Slab” model, the designer should For this case, the density would be: (kg/m3) Loads (kg/m3) (N/mm2) (N/mm2)

select the “Materials” screen from the navigation menu, 25 MPa 2400 Density 15 20
2400 kg/m3 × (1-0.17) = 1992 kg/m3
Figure 7: 32 MPa 2400 Density 20 25
Note: the design density of normal concrete is specified by
40 MPa 2400 Density 20 32
AS3600-2009, Section 3.1.3 as 2400kg/m3. In practice, the
40 MPa 2400 Density 20 40
actual density of concrete changes with the concrete and
50 MPa 2400 Density 20 50
aggregate specifications, quantity of reinforcement and other
65 MPa 2400 Density 20 65
properties.
40 MPa Austral Deck
2400 Density 20 32
The designer should also take care to check if the density Bathroom Setdown
properties are used in calculation for any other structural
Table 4 – Reduced Austral Deck densities for regular and bathroom
properties that might impact the results of the analysis. slab areas

In the case of RAM Concept, it is possible to specify a separate

Density property from Density For Loads calculation. It is
highly recommended that the designer run the analysis for
both options and check if any differences in the results are
significant to the calculations.
It is also important that the concrete strength and stiffness
characteristics, such as f’ci, f’c, Eci and Ec remain the same as
the traditional concrete mix – these will be altered later.
3.3.3. Reduced Concrete Stiffness
Different software packages have the ability to directly
influence concrete stiffness either globally or locally in certain
areas of the slab.
Structural stiffness is proportional to both material (Young’s
Modulus E) and geometric stiffness (Moment of Inertia I).
The material stiffness values were unmodified in the material Figure 8 – Slab properties showing Austral Deck concrete mix and custom
settings above, as the concrete material is not actually reduced stiffness

changing when using Austral Deck.

Figure 7 – RAM Concept Menu RAM Concept can modify geometric stiffness by altering the
slab thickness or directly with modification coefficients.
Density Density For Loads f 'ci f 'c f 'cui f 'cu Poisson's User Eci User Ec
MIX NAME Ec Calc
(kg/m3) (kg/m3) (N/mm2) (N/mm2) (N/mm2) (N/mm2) Ratio (N/mm2) (N/mm2) It is the designer’s prerogative as to which option is modified,
20 MPa 2400 Density 15 20 18.75 25 0.2 Code 21000 25000 but one should always remember the flow-on effects of each
25 MPa 2400 Density 20 25 25 30 0.2 Code 25000 27000 option. For instance, reducing the slab thickness in RAM
32 MPa 2400 Density 20 32 25 40 0.2 Code 25000 31000 Concept would directly reduce the structural self-weight, and
dramatically reduce the capacity calculations for Bending
40 MPa 2400 Density 20 40 25 50 0.2 Code 25000 34000
Moment, Beam Shear and Punching Shear.
50 MPa 2400 Density 20 50 25 60 0.2 Code 25000 38000
65 MPa 2400 Density 20 65 25 80 0.2 Code 25000 43000
32 MPa (Austral Deck) 2400 Density 20 32 25 40 0.2 Code 25000 31000

Table 3 – RAM Concept Concrete Mix Properties

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 AUSTRAL PRECAST Austral Deck TECHNICAL GUIDE

3.3.4. Isotropic vs Orthotropic Stiffness 3.3.6. Orthotropic Stiffness and Australia Code 3.3.7. Austral Deck and RAM Concept Design Strips Axial Forces
Compliance Axial forces are sometimes taken into account, depending on
When modelling a suspended slab in a finite element software RAM Concept uses Design Strips to integrate design actions
the design strip settings, however for “T”, “L”, or “Z” beams,
environment, it is often possible to adjust the individual It is imperative that any variation to the slab stiffness takes such as bending moments, shears and support reactions and
Austral Deck designers should take care that the design strips/
stiffness coefficients separately. into account both the actual, real-world differences in the create a one-dimensional span. The design or span is then
sections include the entire beam flange area, otherwise
structural properties of the slab, but also the limitations split into several regular cross sections which are analysed.
In the case of RAM Concept, Figure 7 shows the 6 degrees of significant out-of-balance axial forces will be applied into the
imposed by any relevant design codes and standards.
slab movement, as follows: Reinforcement quantities (in mm2) are determined for the plank zones of the Austral Deck slab.
For instance, Australian Standards AS3600-2009 describes design load envelopes over the design cross section. Finally,
• K Mr Bending stiffness about primary direction Reinforcement depth
methods for structural analysis in Section 6. In particular, the software takes all the design sections along a particular
(about R axis) Austral Deck designers should carefully specify the design
Section 6.9 describes the use of Idealised Frames, whereby span and applies code compliant detailing rules to lay out the
• K Ms Bending stiffness about secondary directory location and actual location of the Layer 2 reinforcement, i.e.
positive and negative moments in both primary and secondary reinforcement.
(about S axis) the bars placed on the bottom of the in-situ slab, sitting
axes are apportioned to column and middle strips.
3.3.8. R AM Concept and AS3600-2009 directly on the bottom of the precast plank. In some cases,
• K Mrs Torsional stiffness
RAM Concept enables the designer to split the suspended Implementation these bars may not be properly included as bottom face
• K Fr In-plane axial/membrane stiffness in primary
slab into various design strips. If design strips are set up reinforcement.
direction The designer should be aware of the various inclusions and
automatically, RAM Concept will default to using “Code Slab”
exclusions that RAM Concept applies and ensure that 3.3.9. Austral Deck and RAM Concept Deflection
• K Fs In-plane axial/membrane stiffness in secondary layout rules, which generally apportion the strips in
adequate hand-checks are performed to make sure there is no Analysis
direction accordance with AS3600, Section 6.1.
AS 3600—2009 78 areas of the slab that are excluded from the run.
• K Vrs In-plane shear stiffness Accurate prediction of slab deflections can be a difficult task
For instance, RAM Concept does not apply all the various and is dependent on both analysis and design parameters
Where custom coefficients are used, the orientation of the
requirements from AS3600-2009, or applies its own including:
R-axis is critical.
interpretations of some of the various design requirements.
For Austral Deck slabs, it is good practice to orientate the • L oading and load history estimates over short term (days)
This is detailed in the RAM Concept manual.
R-axis in the direction of the Austral Deck plank. Whilst and long term (years)
Some of the design limitations that RAM Concept applies are
Austral Deck has been designed to be a two-way suspended • Estimation of slab cracking and effective/transformed slab
pertinent to Austral Deck designs, as follows:
slab system, the planks, voids and joints interact such that the section properties
direction of the deck is considered the stronger and stiffer Initial Service Load Case • Tension and compression reinforcement ratios
direction. RAM Concept does not take into account the differential age
• Interaction between cracked concrete slabs and
between the precast plank and topping portion of Austral
For RAM Concept, if all coefficients are 1, the slab is perfectly reinforcement
Deck.
isotropic, or two-way spanning. Whereas, for an idealised • Estimation of creep and shrinkage properties
one-way slab, RAM Concept defaults to Concrete modulus
• Estimation of short and long term concrete strength and
RAM Concept uses the formula for Ec and Eci as specified by
KMr = 0.001 and KMrs = 0.5. stiffness (as design compared to as-constructed)
Figure 9 – Design column and interior strips as TWO-WAY
defined bySLAB
AS3600-2009 the equations in AS3600-2009 Section 3.1.2, not the values
3.2.5. Austral Deck and Orthotropic Stiffness
FIGURE
Section 6.1.
6.1.4(A) WIDTHS OF STRIPS FOR SYSTEMS
• Estimation of concrete rates of strength gain over 24 hours,
specified by Table 3.1.2.
30 days and 30 years.
In an ideal design, Austral Deck is considered to be almost f 'cm values used in the equations, however, are taken from
• Slab age at de-propping and loading
isotropic. As Table 1 indicates, the difference between strong For Austral Deck designs, the use of primary and secondary Table 3.1.2. in AS3600.
and weak axis reductions is subtle. In the case of AD250 the stiffness modifiers will significantly influence the RAM Concept provides load history calculations which are
apportionment of load and therefore bending moment into the Low Ductility Rebar then reconciled to the cracked section analysis in orthogonal
difference is 93% compared to 91%.
column and middle strips. RAM Concept does not apply the low ductility (Class L) rules directions. (Figure 10).
Accessed by R O BIRD AND ASSOCIATES PTY LTD on 21 Dec 2009

In practice, for longer Austral Deck spans, plank dimensions that were updated as part of Amendment #2 of AS3600-2009.
may be 8-9m x 2.5m. This results in 3-4 times more plank The designer should take care to ensure that the moment This is particularly relevant for the mesh reinforcement placed
joints in the secondary direction than the primary direction. redistribution does not exceed the limits of redistribution that within the precast section of Austral Deck.
is allowed by the code. For instance, AS3600-2009 Table
For properly (and ideally) laid out slab plans, the cumulative Minimum Reinforcement
6.9.5.3 limits the moment distribution as follows in Table 5:
impact of the joints may reduce stiffness (and increase RAM Concept uses AS3600-2009 Section 8.1.6 and Section
deflection) by as much as 5% over larger spans. This also has 9.4.3.2 for minimum reinforcement in span directions.
Distribution of Bending Moments to the Column Strip
the effect of redistributing primary and secondary direction Section 9.1.1 is implemented via Section 8.1.6.1 for spanning
Bending Moment Under Strength Servicability
moments which will alter the reinforcement design and Consideration Limit State Limit State reinforcement. This may result in different reinforcement
placement. Negative moment in an interior quantities in Austral Deck planks.
0.60 to 1.00 0.75
support
FIGURE 6.1.4(B) SPAN SUPPORT AND SPAN LENGTHS FOR FLAT SLABS

Negative moment in an exterior Crack Control

0.75 to 1.00 0.75
support with spandrel beam
© Standards Australia www.standards.org.au AS3600-2009 Section 9.4.1(c) and (d) are ignored when the
Negative moment in an exterior slab environment is specified as “protected”, which is the
0.75 to 1.00 1.0
support without spandrel beam
Negative moment in an interior typical setting for internal slabs. This may be unconservative
0.50 to 0.70 0.6
support for Austral Deck slabs and should be checked manually.

Table 5 – Design strip distribution from AS3600-2009 Table 6.9.5.3

Figure 10 – RAM Concept load history options

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 AUSTRAL PRECAST Austral Deck TECHNICAL GUIDE

It is important for the designer of Austral Deck to take into
account some particular deflection characteristics which may
influence the deflection calculation, as follows:
• The RAM Concept creep and shrinkage models are derived
from ACI report 209R-92. There is significant literature
online for this deflection model, however it is important to
note that the ACI model assumes the initial loading time is 7
days, whereas AS3600 assumes initial loading is 28 days.
Designers should either use the ACI model and specify the
actual time of loading, or use the AS3600-2009 final creep
factors from Table 3.1.8.3, and then multiply by 1.326, which
is (k3-7days / k3-28days).
• Designers should also note that the creep factor includes
elastic strain + creep strain.
• Shrinkage Restraint plays an important role in deflection.
Online guidance from RAM Concept is as follows:
• Generally, shrinkage restraint for Austral Deck should be set
between 10 and 15% depending on the level of conservatism
required for deflection calculations.
• Whilst designers usually ignore the live load reduction
factors settings in RAM Concept, it is important to set live
loads to their correct load case (Reducible, Unreducible,
Storage, Parking, Roof). RAM Concept uses these cases to
determine short and long term combination factors in
accordance with AS1170.0 Table 4.1. These are then used for
the load history. For example, setting residential loading to
“unreducible” would apply ψL=0.6 and ψS=1, rather than
ψL=0.4 and ψS=0.7. This would obviously increase the
deflection over the long term.
• R AM Concept defaults to using 5000 days (132/3 years) for
long term deflection, but AS3600 conventions suggest 30
years, or 10950 days.
3.4 Austral Deck Design Strip Layout in
RAM Concept
This section discusses some of the modelling options available
to Austral Deck designers using RAM Concept.
3.4.1. Example Design
The example design used in this section has been chosen to
demonstrate some design strip layout options, and does not
represent a real-world model.
To ensure the terminology of RAM Concept remains
consistent, we will refer to the slab axes as Latitude, running
horizontally to the page, and Longitude, running vertically to
the page.
The layouts are only suggested for various designs, and could
easily be reconfigured to suit the Austral Deck designer’s own
preferences.
The slab contains 3 spans of 8m, 6.5m and 8m respectively in
the Latitude direction, and 2 spans of 6.5m in the Longitude
direction. (Figre 11–12)
The overall floor is 250mm thick Austral Deck, with 40mm
bathroom set-downs. There are 200mm wide, 1000mm deep
upstand beams on two sides of the model.

> 0% - unrestrained or very lightly restrained slabs

(flexible columns only, single stiff element)

> 10% - normally restrained slabs (more than one stiff

element, some flexibility)

> 20% - completely restrained slabs (basement walls

around entire perimeter, etc. causing a high degree of
restraint)

3.3.10. Example – Austral Deck Load History Settings

Table 6 is a set of load history settings that might be typical of
a residential slab (average 250mm thick, 32MPa, coastal
environment).
Variation in these settings, combined with an abundance of
localised environmental effects will give rise to differences in
real-world experiences of deflection. It is highly recommended
that conservative values are chosen, and that the designer
undertake sensitivity analyses with different values to check
that the slab design is sufficiently conservative.

Setting Value Comments

Figure 11 – RAM Concept strip layout example

Live Load 1.5kPa (reducible) As per AS1170.1, to ensure short and long term factors are correct

Load History –Sustained 10950 days Equal to 30 years for total long term

Initial Load Application 7 days As per RAM Concept Recommendations

For example, a residential slab, precast concrete party walls and a sheer core,
Shrinkage Restraint 15%
but free to shrink on the edges

Design creep factor from AS3600-2009 using:

Creep Factor 3.8
F'c + 32, th = 250, t = 10950, k2 = 1.127, k3 = 1.463 φ*cc = 2.8, Design creep = 1 + φ*cc

From AS3600-2009, using basic shrinkage ε*ccsd,b = 1000µε,

Shrinkage Strain 0.000462
based on aggregate supply from "elsewhere'

Table 6 – Typical load history settings for a residential Austral Deck slab Figure 12 – RAM Concept strip layout - 3D render

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 AUSTRAL PRECAST Austral Deck TECHNICAL GUIDE

3.4.2. Flat Plate

Flat plate slabs can be modelled as individual strips or as
individual Austral Deck planks.
In this case the 250mm Austral Deck slab was modelled with a
17% reduction allowance for voids, but the bathrooms were
modelled with 11% reduction, using 210mm thick slabs,
roughly based on the reduction factors from Table 1.
RAM Concept priority numbers were used (higher priority
numbers are meshed in preference to lower numbers), as
follows:
• Upstand beams, full density, priority 5, meshed as slab
elements
• Bathroom areas, latitude orientation, priority 3
• General primary spans, longitude orientation, priority 2
• General secondary spans, latitude orientation, priority 1.

Figure 14 – Example plank layout #1

Figure 13 – Example model showing mesh area layouts

Figure 13 presents a reasonable mesh for Austral Deck,

however does not provide a very cost effective plank layout, as
seen in Figure 14. There are eight primary Austral Deck
planks and 18 secondary planks, which are quite short.

Figure 15 removes one of the primary planks and extends the

secondary planks, reducing the total plank count to 18, saving
eight planks in total.

The Austral Deck designer must consider that extra planks

require extra propping, transport and lifting requirements,
and increase the number of joints visible in the soffit of the
slab.
Figure 15 – Example plank layout #2

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 AUSTRAL PRECAST Austral Deck TECHNICAL GUIDE

The design strip layouts in Figure 15 follow the plank layouts
at left for latitude and longitude strips. They are all designed
as “slab rectangle” strips, with the exception of the upstand
beams.
Some of the other characteristics of the strips in Figures 16
and 17 are:
• A ll latitude strips have their reinforcement covers set to
minimum – i.e. the designed reinforcement allows for
bottom bars to be located in the plank. The designer should
note, however, that the planks in the latitude direction stop
short by the width of the column planks spanning in the
longitude direction. Bottom layer reinforcement at this point
would not be in the critical section, but needs to be checked
nonetheless. Further detailing rules for these circumstances
are shown in Section 4.
• Latitude strips have been set to roughly 2.4m wide,
mirroring the plank layout, however the strips are shifted
such that they are centred on the columns lines. This means
that the edge designs (span 1-1 to 1-4 and 7-1 to 7-4) would
actually be “half-strips”. The designer could either bear this
in mind when detailing the reinforcement on structural
drawings, or could adjust the strip boundaries manually to
exactly mirror the plank layout.
• L ongitude strips follow the traditional Column Strip/Middle
Strip layout as specified by AS3600. These strips would be
stiffer as they are generally shorter spans and as such the
designer should take advantage of AS3600 detailing
guidelines for positioning of rebar within the effect
compression width of the column strips. Further details are
shown in Section 4.
• L ongitude strips for the upstand planks are set as “Inverted
L” beams, however the designer should consider using
manual design sections to ensure the top dimension is cut off
to 200mm above the slab surface level. This enables Austral
Deck to provide the upstand plank with a short hob and the
remainder of the upstand as a precast wall element.

Figure 17 – Longitudinal sections generated from design strips

Figure 16 – Latitude and longitude design strips

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 AUSTRAL PRECAST Austral Deck TECHNICAL GUIDE

3.4.3. Banded Slab
A banded slab (Figure 18 & 19) represents a more specific use
of Austral Deck, most likely to be found in carparks,
commercial buildings or transfer floors.
The deeper bands effectively configure the slab into a series of
one-way spanning beams and one-way spanning slabs. If the
spans between the beams are sufficiently long, Austral Deck
provide an ideal design to limit formwork and propping and
speed up construction cycles.
The design strips in Figure 20, particularly in the longitudinal The adjustment also removes the upstands on the edges from
direction are not altered in layout, however designating the the concrete section calculations, in favour of the downstand
The deeper bands (usually in the order of two times to three strips as “beam” adjusts the effective strip width, in band. Note that the stiffening effect of the upstands, including
times the slab depth) are still sufficiently wide to enable accordance with AS3600-2009 Section 8.8. bending moment distribution is still taken into account.
flexural capacity in their transverse direction, however there
would not usually be any voids present in the bands. The
bands, therefore, are specified with normal, rather than
reduced density, concrete materials.

8 6.5 6.5

Figure 20 – Longitude strip layout for banded slab

6.5

When properly reinforced and detailed, the above design produces a deflection profile as follows:
R

S S S
R R R R R R
S

S S S
R
6.5

Figure 18 – Banded slab layout

Figure 21 – Banded slab deflection profile

The maximum slab deflection in this case is 32-35mm, which

is Span/295 for a 10m span. This is considered reasonable as
far as span-to-deflection ratios, but generally would be
Figure 19 – Banded slab 3D render (viewed from below) considered 5-10mm too large in absolute deflection terms.

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 AUSTRAL PRECAST
4. AUSTRAL DECK AND AS3600 DETAILING
REQUIREMENTS
The following chapter discusses some of the more specific
requirements of AS3600-2009, Concrete Structures. The
standard has specific design and detailing requirements that
all designers are required to check as part of the normal
design process.
This chapter will discuss those requirements, and how they
impact the design of Austral Deck slabs.
4.1 Concrete Cover
4.1.1. Code Requirements
The cover requirements for Austral Deck slabs are the same
as for any normal reinforced concrete element, with one
exception.
Minimum cover to the base (soffit) and sides of the Austral
Deck precast plank can be taken from AS3600-2009, Table 8
in this guide, rather than Table 4.10.3.2. This is justified as the
Austral Deck planks are cast on rigid steel casting beds,
off-site in a precast concrete factory. It is assumed (and should
always be checked by the design engineer), that the precast
factory will employ rigorous quality control and checking
procedures.
The minimum cover requirements for environmental
conditions, as detailed in AS3600-2009 Table 4.8.1 and Table
4.8.2 should always be adhered to, for Austral Deck slabs close
to or in contact with the ground, especially in aggressive soils.
Careful reinforcement laying directions should be followed for
the general mesh, especially with the standard 60mm Austral
Deck biscuit thickness. These are represented in Figure 22.
Figure 22 – Cover requirements for Austral Deck planks
/ 30 /
The Austral Deck designer should also check the exposure and
durability requirements for the Austral Deck planks,
especially for the soffits of external elements such as
balconies.
Table 4.3 of AS3600-2009, (Table 7) in this guide, details the
exposure classification for various concrete elements. Section
4 of the Standard indicates the most common elements that
would be used for Austral Deck planks.
Surfaces of members in above ground exterior
environments in areas that are:
(a) Inland (>50 km from coastline) environment being:
(i) Non-industrial and arid climatic zone
(ii) Non-industrial and temperate climatic zone
(iii) Non-industrial and tropical climatic zone
(iv) Industrial and any climatic zone
(b) Near-coastal (1 km to 50 km from coastline),
any climatic zone
(b) Coastal and any climatic zone
Table 7 – Extract from AS3600-2009, Table 4.3 - Concrete Exposure
Classification
Required cover where repetitive proceedures
and intense compaction or self-compacting concrete are
used in rigid formwork
Required cover, mm
Exposure
Characteristic strength (f 'c)
classification
20 MPa 25 MPa
A1 20 20
A2 (45) 30
B1 – (45)
B2 – –
C1 – –
C2 – –
Table 8 – Extract from AS3600-2009 Table 4.10.3.3 - Concrete Cover
Referencing the above tables from AS3600-2009, Austral Deck
projects in tropical climatic zones, or any Austral Deck planks
located externally and within 50km of the coast would be
defined as B1. These require minimum 25mm cover for 40MPa
concrete in accordance with AS3600. Note: tropical zones are
also defined in AS3600, and generally refer to areas North of
20°S in Western Australia and Northern Territory, North of 23°
in Queensland.
Austral Deck TECHNICAL GUIDE
4.2 Ductility Requirements in Flexural
Reinforcement
(ii) shall not be used in any situation where the reinforcement
is required to undergo large plastic deformation under
Ductility requirements are one of the fundamental concerns of
strength limit state conditions.
Generally, throughout the code, the use of low ductility
well designed, conservative concrete structures in accordance
with Australian (and most international) codes and standards. reinforcement, such as SL and RL grade meshes is expressly
forbidden. However, Section 6 of AS3600-2009 provides
The general ductility principle requires structures that have
design guidance as to the use of “L” grade reinforcement.
been loaded beyond the point of failure to deflect significantly
Essentially, positive design moments are increased by up to
without collapse, so as to provide sufficient warning to their
10%, (for example wL2/16 becomes wL2/14), and moment
occupants to evacuate.
redistribution is not allowed.
AS3600-2009 specifically addresses some ductility concerns.
Austral Deck uses a combination of low ductility (L) and
The changes to the code should be carefully considered in all
normal ductility (N) reinforcement for the primary positive
Austral Deck designs.
(mid-span) bending moments, and normal ductility
AS3600-2009 section 1.1.2 requires: reinforcement for the negative bending moments, over
supports.
Reinforcing steel of Ductility Class L in accordance with AS/
NZS 4671— It is the Austral Deck designer’s responsibility to determine
the ratio of L to N ductility. One suggestion is to provide
(i) may be used as main or secondary reinforcement in the
sufficient N grade reinforcement to comply with ultimate loads
form of welded wire mesh, or as wire, bar and mesh in
A1 under “fire” or “earthquake” load conditions. This is typically
A2 fitments; but
W* = DL + 0.3 x LL in accordance with AS1170.0.
B1
B1
B1
B2 4.3 Reinforcement Laying Sequence
Whilst the reinforcement laying sequence will primarily be Reinforcement is usually referred to as Layers 1 through 5,
defined by the plank span direction, the sequence of the top or B1/T1, depending on the normal naming conventions of the
reinforcement layers are somewhat more flexible. Austral Deck designer. These are detailed in Figure 23:
32 MPa 40 MPa ≥50 MPa
20 20 20
20 20 20
30 25 20
(50) 35 25
– (60) 45
– – 60
Figure 23 – Reinforcement bar laying sequence
For Austral Deck slabs, layers 1 and 2 are cast into the precast These bars are usually threaded through gaps in the trusses.
concrete plank. Splice bars on layer 3, along with any
Finally, layers 4 and 5, are placed and tied in the top layer in
additional secondary reinforcement is placed on the surface of
the same manner as a typical in-situ poured concrete slab.
the plank once the Austral Deck has been positioned on site.
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 AUSTRAL PRECAST Austral Deck TECHNICAL GUIDE

4.4 Detailing of Span Direction 4.4.3 Negative Reinforcement

Reinforcement
Primary reinforcement detailing in accordance with AS3600 is
specified in section 9.1.3.1 for suspended slabs. This includes,
among others, the following key requirements:
• Requirement for anchorage of positive (bottom) flexural
reinforcement at end supports – generally at least 50% of the
total flexural reinforcement, anchored to at least the larger 12
bar diameters or D, the slab thickness.
• Requirement of at least 25% of the positive (bottom) flexural
reinforcement to extend past the near face of an internal,
continuous support point, typically to full anchorage of 25 bar
diameters.
4.4.1 End Supports
4.6 Calculation of Splice Bars
Standard detailing rules remain applicable for the
conventionally laid, negative or top layers of reinforcement. The calculation of splice bar quantity and length is required to
be carefully determined for Austral Deck slabs, as traditional
One critical such rule is AS3600-2009, Section 9.1.2,
“lapped splices” are not usually applicable. (Figure 25)
Reinforcement and tendon distribution in two-way flat slabs.
In two-way flat slabs, at least 25% of the total of the design
negative moment in a column-strip and adjacent half middle-
strips shall be resisted by reinforcement or tendons or both,
located in a cross-section of slab centred on the column and of
a width equal to twice the overall depth of the slab or drop
panel plus the width of the column
Given that the majority of Austral Deck slabs are two-way,
with generally flat soffits, the above requirement will most
likely apply.

For Austral Deck planks supported by a precast concrete wall,

the first requirement can be met by the following:
1. Provide screw-in ferrules, rip-boxes or other proprietary
reinforcement equivalent to at least 50% of the flexural
reinforcement.
2. Provide a full lap of ferrules with the bottom reinforcement,
as per AS3600 Section 13.2, to a minimum length of Lsy.t.lap
For planks supported by masonry or brickwork, this can be
achieved by providing cogs on the primary bottom
reinforcement, as the cogs will provide 50% anchoring in
accordance with AS3600 Section 13.1.2.6
4.4.2 Internal Supports
At internal columns or walls, at least one quarter of the flexural
bottom reinforcement should be extended past the face of the
support. This will require additional splice bars to be added to
the Austral Deck once it has been installed on site. Refer to
Section 4.6 in this guide for notes on calculation of splice bars.
Figure 24 below shows a typical splice bar detail at an internal
column location. Note that only 25% of the flexural bars are
required to be spliced.
4.5 Detailing of Cross Direction
Reinforcement
If the Austral Deck designer reduces the stiffness of a two-way
slab to 50% or less, then it is likely that the secondary
direction reinforcement requirement will be almost entirely
met by the cross rods of the mesh cast into the precast plank.
Typically, for SL92* mesh, this is 287mm2/m, or the
equivalent of N12 rebar at 400mm centres.
The designer will need to be mindful of ductility requirements
(refer to section 4.2 ).
The number of splice bars required for the cross direction
reinforcement would then be calculated as a proportion of the
cross direction reinforcement. For instance, if 180mm2/m
reinforcement is required and 287mm2/m is provided, then
splice bars the equivalent of N12 at 600mm centres would be
required, providing 183mm2/m. This is equivalent to splicing
every third rod from SL92* (8.55mm bars).
* The common mesh size used for manufacturing Austral Deck is SL72.
Figure 25 – Splice bar calculation of forces
4.7 Punching Shear
4.7.1 General Design Issues
Punching shear for Austral Deck slabs needs to be carefully
designed and checked, especially with larger, flat-plate type
slab designs.
In Australia, it is generally accepted design practice to either
use AS3600 Section 9.2 or to use the Eurocode EN 1992-1-1
Section 6.4.4
Both of the above design methods have significant bodies of
research behind them, and are not compared specifically in this
manual.
In general, Australian Standard AS3600 treats punching shear
using closed reinforcement ties laid in a torsional design strip
across the column. The detailing requires the ties to be placed
over a quarter-span in each direction to adjacent columns.
4.7.2 P unching Shear Reinforcement and Austral
Deck
For Austral Deck slabs, it is usually simpler to use the
Eurocode to both check and design for punching shear, and
the use of shear studs rather than closed ligatures is certainly
easier for installation.
Where required, the punching shear studs can be installed
into the precast biscuit in the factory to a precisely laid out
position, and generally do not interfere with the trusses or
bottom reinforcing.
It is critically important that all void formers are removed
from the punching shear perimeter, however wide that may
be. This in turn will impact the total slab weight and may
require recalculation of run-down loads to columns and
foundations, all of which should be taken into account by the
Austral Deck designer.

The Eurocode (and the old British Standard 8110) models a
series of concentric shear planes or rings progressing outwards
from the column in question. Vertical shear reinforcement is
placed in a cruciform or radial pattern outwards from the
column until the punching shear perimeter is sufficient large
enough to carry the load. The reinforcing is usually in the form
of individual hooks or “S” shape rebar, or proprietary studs
tack-welded on to light bars such as Ancon Studrail.
Figure 24 – Typical internal support splice bar locations
4.7.3 Basic Punching Shear Checks
Prior to undertaking detailed checks and design, it is often
useful to determine a basic punching shear capacity around
the columns. For this purpose either Australian or European
codes can be used.
The Austral Deck designer should establish the capacity of the
topping component of the Austral Deck, excluding the precast
biscuit. This is considered the absolute minimum capacity as it
ignores up to 60mm (or 90mm) of the concrete depth.

/ 32 / / 33 /
 AUSTRAL PRECAST Austral Deck TECHNICAL GUIDE

For instance, a 500x500 concrete column supporting a The designer can then deduce that the column tributary load 4.8 Longitudinal Shear For instance, taking the example from Section 4.7.3. where the
275mm thick N40 Austral Deck slab has the following capacity area is approximately 731.7/10.47 = 69.9m that could be
2 total load on the slab is 10.47kPa, and we assume a single span
In zones of high transverse loads, longitudinal shear can
in accordance with AS3600. carried by the topping portion of the slab alone with no of 7.5m and tributary width of 6m.
become significant for any composite structure, including
punching reinforcing. wL 7.5
ØVuo = Øudom (fcv + 0.3σcp ) Austral Deck. V* = = 10.47 × 6 × = 235.5kN
2 2
(
fcv = 0.17 1 +
2
βh
)
√ f’c ≤ 0.34 √ f’c
If using AS3600 section 9.2.4, there are further reductions
due to the torsional moments across the column,
In the case of Austral Deck, the shear can be resisted by the
BD3 6000 × 0.275 3
Ixx = = = 7812.5 ×106 mm 4
approximately equal to uMv* which need to be considered.
friction interface between the in-situ topping slab and the
σcp = 0 (slab is not tensioned) 12 12
8V* adom precast biscuit or by the rebar trusses, or both.
βh = 1 (square column aspect ratio)
4.7.4 Punching Shear Using Rebar Trusses
Calculation of the longitudinal shear follows the formula for Q60mm = (60 ×6000) × ( 250
2
–
60
2
)= 34.2 × 10 mm
6 3

fcv = 0.34√40 = 2.15MPa Shear Flow:

( )
12mm It is possible to consider the full depth of the Austral Deck slab V* Q 235.5 × 34.2 × 106
dom = 179mm 275mm – 30 cover – – 60mm planket q= q= = 1.031kN/mm
2 for punching shear, using the rebar trusses as shear ties. I 7812.5 × 106
Generally, the design for this should be undertaken using the
u = 4 ×(500 + dom ) = 4 × (679) = 2716mm
Eurocode provisions, and would require careful checking. Where: q is the longitudinal shear, or shear flow, in kN/mm
If the longitudinal shear force from the above calculation is
ØVuo = 0.7 × 2716 × 179 × 2.15 = 731.7kN
Usually, however, the spacing of the trusses and lack of truss V* is the transverse shear force (kN) resisted over 6m width by 9 rebar trusses, each with 2 x N6
For a 275mm Austral Deck slab, carrying residential loads continuity over column supports precludes their inclusion in rebar at 100mm centres then the shear resistance provided by
Q is the first moment of area at the shear interface
(1kPa SDL and 1.5kPa LL) with self-weight of 5.85kPa the punching shear calculations. the trusses is:
(mm3)
(based on 15% void ratio), the total ultimate slab weight is 0.8 × 500MPa × 28mm2 × 18 bars
I is the moment of inertia above the natural axis ØVlong = = 2.02kN/m resistance
1.2 (5.85 + 1) + 1.5 (1.5) = 10.47kPa. 100 mm spacing
(mm4)
In this case the shear resistance of the rebar is sufficient to
resist any longitudinal shear forces at the in-situ/precast
4.7.5 Alternatives for Punching Shear interface.

If punching shear becomes too great to be able to be supported
by the topping slab alone, and shear ties/studs are impractical,
it may also be possible to pour a localised “mushroom head”
(Figure 26) around the column, where the precast slab is cut
back roughly 100mm and the entire depth of concrete is used.
For instance, taking the previous example, if dom were
increased by 60mm to 239mm, then the shear perimeter u
becomes 4(500 + 239) = 2956mm. Punching shear capacity is
increased by approximately 45%
ØVuo = 0.7 × 2956 × 239 × 2.15 = 1063kN

Figure 26 – Punching Shear Setback

/ 34 / / 35 /
 AUSTRAL PRECAST
5. AUSTRAL DECK DESIGN AS FORMWORK
This section is to demonstrate the process of designing Austral
Deck as formwork complying with the stability, strength and
serviceability limit stage criteria specified in AS3610-1-2010
Formwork for Concrete – Part 1 Documentation and surface
finish.
The process is used to determine the maximum spanning
capacity of Austral Deck based on the structural properties
and construction loads in order to define the temporary
propping requirement of a concrete slab constructed using
Austral Deck.
The specifc calculations in this document apply to a simply
supported double span Austral Deck panel for the variable
structural properties and construction loads listed on 5.3.1.
However the calculations also provide guidance for other
situations.
Charts 2 and 3 in 5.4.8 and 5.4.9 can be used as a guide for
Austral Deck as formwork under construction loads for
various slab thickness and steel lattice girder reinforcement
con gurations.
Austral Deck – Construction Load Analysis software can be
used to determine prop spacing for a variety of structural
properties and construction loads.
The software can be downloaded via the Austral Precast
website www.australprecast.com.au
EQUAL SPAN
Figure 27 – Interior Support During Construction
/ 36 /
5.1 Stage one: Design as formwork
The precast element of Austral Deck must be designed as
formwork for construction loads since it is utilised as
permanent formwork. The strength of the precast element
required to span between temporary and permanent supports
during construction is gained from the lattice girder type
reinforcement that is partially embedded in the precast
concrete.
The top chord of the lattice girder type reinforcement is not
embedded in the precast concrete so Austral Deck must be
designed as formwork using a combination of the Australian
Standard for Concrete Structures (AS3600-2009) and Steel
Structures (AS4100-1998) along with the Australian standard
for loading (AS1170) and formwork (AS3610-2010).
It is recommended that the design engineer uses strict
deflection criteria when designing as formwork for
construction loads to alleviate any significant cracking.
EQUAL SPAN
Austral Deck TECHNICAL GUIDE
5.2 Design Criteria and Specifications 5.2.3 Surface Finish
5.2.1 Strength The surface finish of the panel soffit conforms with the
physical quality of a “Class 2” surface finish as specified in
The Panel must resist the bending and shear action effects AS 3610.1 – 2010. The surface class chosen for the in situ
from all the appropriate load combinations.In the case of a slab is also used to define the maximum allowable deflection
simply supported panel the following load combinations are limits.
appropriate.
5.2.4 Panel Capacity
Stage I – prior to placement of concrete
1.25G+1.5Quv+1.5M1 (1) The strength and stiffness of the panel is dependent on the
truss, panel size and geometry. During construction the
Stage II – during placement of concrete
applied loads are resisted by the action of the truss members
1.25G + 1.25G c + 1.5Quv + 1.5M2 (2)
and panel concrete. The resistance provided by any mesh or
1.25G + 1.25G c + Qc (3)
additional reinforcement bars is ignored.
Stage III – after placement of concrete
1.25G + 1.25G c + 1.5Quv + 1.5M3 (4) The following structural checks are performed:
If the panel is considered a primary member as per a) Top Chord Compression
AS 3610 – 1995, then these loads must be multiplied
by a factor of 1.3. For example: b) Top Chord Tension
c) Bottom Chord Compression
Stage I – prior to placement of concrete
1.3(1.25G + 1.5Quv + 1.5M1) (5) STRENGTH d) Bottom Chord Tension
e) Concrete Panel Compression
5.2.2 Stiffness
f) Diagonal Compression
The panel stiffness must be such that the deformation under
the appropriate load combination does not exceed chosen g) Concrete Tensile Strength
limits, using either the limits specified in AS 3610.1 – 2010, a) Deflection
Table 3.3.2 (Form face deflection) or otherwise chosen. In SERVICE
the case of a simply supported panel the following load b) Cracking
combinations are appropriate:
The maximum allowable span is calculated for each case.
Stage II – during placement of concrete
G + G c + Quv (6)
Stage III – after placement of concrete
G + G c + Quv + M3 (7)
While AS 3610 – 1995 does not require the addition of Quv, it
has been added to be in line with the intentions of AS 1170.0
– 2002.
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 AUSTRAL PRECAST Austral Deck TECHNICAL GUIDE

5.2.5 Maximum Span 5.2.7 Assumptions 5.3 Panel Properties 5.3.3 Design Load

The maximum span is selected on the basis that the design 1) Vertical and horizontal action effects from environmental Overall Slab Thickness, d = 250 mm Therefore the design loads are as follows:
action, calculated from the factored load combinations, does loads have been ignored (e.g. wind uplift, river currents).
Minimum Cover to Strength, w* = 19.76 kPa
not exceed the capacity of the panel. If relevant, appropriate strength and service loads should
Bottom Reinforcement = 20 mm
be calculated with reference to AS 3610 – 1995, Table Service, ws = 11.16 kPa
A summary of the calculations showing the maximum span 4.5.2. Concrete Density, r =
2400 kg/m3
for each action is given in the table below: Concrete Strength at Loading, ƒcm = 20 MPa 5.3.4 Truss Properties
2) The value for stacked materials during Stage I (M1) applies
Concrete Modulus of Elasticity, E cj = 22,610 MPa
MAX SPAN also to Stage III (M3 ) and during Stage II the value for Austral Deck Truss Type, T = T190/12
DESIGN ACTION stacked materials (M2 ) is 0 kPa. Panel Width, b = 2,500 mm
(m) Average Truss Spacing, Ts = 250 mm
Precast Panel Thickness, tp = 75 mm
POSITIVE Top Chord Compression 3.41 3) The effects of form face deflection and construction Truss Height, Th =
192 mm
Number of Truss per Panel, nt = 10
BENDING Bottom Chord Tension 3.37 tolerances can be ignored. Truss Bar Yield Strength, fsyt = 500 MPa
Number of Voids, nv = 0
Top Chord Tension 3.95 4) The deviations specified for form face deflection, Void Width, bv = N/A mm 5.3.5 Top Chord
NEGATIVE in AS 3610.1 – 2010, Table 3.3.2, will be interpreted
Bottom Chord Compression 1.33 Void Thickness, tv = N/A mm
BENDING as the deflection criteria for the panel as per the following Bar Diameter, dt = 11.9 mm
Concrete Panel Compression 5.59 Class of Surface Finish = 2
extract: Area, A t = 1,112.2 mm2
Number of Spans (based on supports) = 2
SHEAR Diagonal Lacing Compression 5.13 Strut Length, L t =
200 mm
SURFACE CLASS DEFLECTION LIMIT The panel concrete properties (ƒcm, Ecj ) are at the time Effective Length, It = 180 mm
Concrete Tensile Strength 2.23
CRACKING 1 Lesser of 2mm or span/360 of lifting from casting beds. Radius of Gyration, rt = 2.98 mm
Flexural Cracking 3.96
2 Lesser of 3mm or span/270
DEFLECTION Serviceability Deflection 3.05 5.3.1 Construction Loads 5.3.6 Bottom Chord
3 Greater of 3mm or span/270
Panel Dead Load, G = 1.87 kPa Bar Diameter, db = 6.3 mm
The maximum span for the given configuration is therefore:
4 Greater of 3mm or span/270 In-situ Slab Dead Load, Gc = 4.29 kPa Area, A b = 623.4 mm2
Maximum Span 3.05m 5 N/A Construction Live Load, Q uv = 1 kPa Strut Length, L b =
200 mm
The bottom chord compression limit can be ignored Concrete Mounding Load, Qc = 3 kPa Effective Length, I b = 200 mm
if the bottom chord is completely embedded in the panel Stacked Materials, M1 = 4 kPa
5) The welds connecting diagonal wires to the top Radius of Gyration, r b = 1.58 mm
concrete for its full length. Control for concrete tension can
and bottom chord of the truss are capable of transmitting Stacked Materials, M2 = 0 kPa
also be ignored as it is based on the uniaxial tensile strength
the full design action effects. Stacked Materials, M3 = 4 kPa 5.3.7 Diagonal Lacing
of the concrete panel rather than the flexural tensile
strength. This implies that the concrete is allowed to crack * Although AS 3610 – 1995 states that the concentrated load Qc Bar Diameter, dw = 6.3 mm
6) Truss geometry is as per the following table:
but is controlled by the limits set out in Section 9.4.1 of will apply over an area of 1.6 x 1.6m, it has been applied over
the full area of the panel. Area, Aw = 623.4 mm2
AS3600-2009. TRUSS WIRE SIZE (mm)
TYPE TOP BOTTOM DIAGONAL HEIGHT
** The loads from stacked materials, M, Angle of Web, q = 62.5 degrees
may apply to one span only.
5.2.6 Stacked Materials Strut Length, L w = 216.5 mm
T90/10 9.5 6.3 6.3 92
The maximum span loadings include factors M1, 5.3.2 Load Combinations Effective Length, Iw = 151.5 mm
M2 and M3 for the live loadings of stacked materials. T110/10 9.5 6.3 6.3 111
AS 3610 – 1995 gives these values as 4.0 kPa for before and Radius of Gyration, rw = 1.58 mm
T150/10 9.5 6.3 6.3 154
after the placement of concrete (M1 and M3 ), and 0 kPa for STAGE LOAD COMBINATION LOAD UNIT EQUATION
during the placement of concrete (M2). T190/10 9.5 6.3 6.3 191 5.3.8 Mesh
T110/12 11.9 6.3 6.3 112 l 1.3 (1.25G + 1.5Quv + 1.5M1)** 12.78 kPa Mesh =
SL72
The maximum span may be increased by decreasing these
loads. In such a case, this lowered load limit must be clearly T150/12 11.9 6.3 6.3 155 ll 1.3 (1.25G + 1.25Gc + 1.5Quv+ 1.5M2)** 11.96 kPa Wire Diameter, d m = 6.8 mm
indicated in the formwork documentation and construction (5)
T190/12 11.9 6.3 6.3 192 ll 1.3 (1.25G + 1.25Gc + Qc)* 15.86 kPa Area, A m =
448 mm2
controlput in place to ensure it is not exceeded.
lll 1.3 (1.25G + 1.25Gc + 1.5Quv + 1.5M3)** 19.76 kPa

STIFFNESS

ll G + Gc + Quv 7.16 kPa (6)

lll G + Gc + Quv + M3** 11.16 kPa (7)

/ 38 / / 39 /
 AUSTRAL PRECAST Austral Deck TECHNICAL GUIDE

5.3.9 Capacity Calculations 5.3.11 Top Chord Tension 5.4 Panel Properties In accordance with AS 3600 – 2009 Concrete Structures,
Clause 8.1.3:
The number of spans (based on the number of temporary In accordance with AS 4100 – 1998 Steel Structures, 5.4.1 Diagonal Lacing Compression
supports) affects the coefficients used when calculating the Clause 7.1 – N*≤ΦA gfy Where Φ =
0.90 Concrete Strength at Loading, f'c = 20 MPa
maximum spans: Where Φ = 0.9 Concrete Strength Factor, a2 = 0.85
Form Factor, k f =
1.00

M* = jw*L 2
L= M* Limit State Capacity, ΦA gf y = 500 kN Section Capacity, Ns=k f A nfy = 311.72 kN Compressive Area Factor, γ = 0.85
jW* Φ=
Truss Height, Th =
192 mm λn =
136.07 0.60

Limit State Moment Capacity, M*tt = 96.09 kN.m aa =

13.93 Effective Cross Section Depth

j1, POSITIVE j2, NEGATIVE ab =

0.50 (equal to panel thickness t p), d = 75 mm
NO. OF SPANS Maximum Span based on Moment
MOMENT MOMENT λ=
143.03 yg =
46.29 mm
Capacity of Top Chord in tension, L tt = 3.95 m
η=
0.42 ku =
0.62
1 0.125 N/A
ξ=
0.78 Limit State Capacity, ΦNc = 1,003 kN
2 0.096 0.125 5.3.12 Bottom Chord Compression
ac =
0.32 Truss Height, Th =
192 mm

≥3 0.101 0.121 In accordance with AS 4100 – 1998 Steel Structures, Limit State Capacity, ΦacNs =
89.21 kN Limit State Moment Capacity, M*pc = 192.6 kN.m
Clause 6.1 – N*≤ΦacNs Maximum Span based on moment
Maximum Span based on shear
Where Φ = 0.9 Capacity of Diagonal Lacing, L ds = 5.13 m capacity of Top Chord in tension, Lpc = 5.59 m

Form Factor k f = 1
5.3.10 Top Chord Compression The maximum span us calculated from the greatest shear at
Section Capacity, Ns=k f A nf y =
311.7 kN
any point along the slab: V* 5.4.3 Control for Concrete Tensile Strength
In accordance with AS 4100 – 1998 Steel Structures, λ n = 179.6 j3w
Clause 7.1 – N*≤Φag N2 V*=j3w*L L= AS 3600 – 2009, Clause 3.1.1.3 defines the tensile strength for a
aa = 11.05
given concrete member, this has been used to ensure that the
Where Φ = 0.9 ab = 0.50 Where j3 is a constant that depends deflection calculations are accurate without using the cracked
Form Factor, k f = 1 λ = 185.11 on the number of spans. second moment of area.
Section Capacity, Ns=k f A nf y =
556.1 kN η = 0.56 NO. OF SPANS j3 f'ct.f 'Ig
λ n = M*pt = where f'ct.f = 0.6 √ f'c
85.57 ξ = 0.68 1 0.5 yg
aa = 18.77 f'ct.f =
2.68 MPa
ac = 0.20
2 0.625 Limit State Moment Capacity for
ab = 0.50 Limit State Capacity, Φac Ns =
56.88 kN
λ = ≥3 0.6 concrete strength, M*pt = 23.61 kN.m
94.95 Truss Height, Th =
192 mm
Maximum Span based on controlling
η = 0.27 Limit State Moment Capacity, M*bc = 10.92 kN.m
to concrete tensile strength, Lpt = 2.23 m
ξ= 1.07 5.4.2 Concrete Panel Compression
Maximum Span based on
ac = 0.58 Moment Capacity of Top Chord Transformed Section:
in compression, Lbc =
1.33 m 5.4.5 Crack Control for Flexure
Limit State Capacity,Φac Ns =
288 kN For serviceability limit state, the panel is analysed as an
Truss Height, Th =
192 mm uncracked section using the Transformed Area method to AS 3600 – 2009, Clause 9.4.1 states the requirements for
determine the stresses in the steel and concrete. crack control in flexure to be deemed controlled. Part (c)
Limit State Moment Capacity, M*tc = 55.28 kN.m
5.3.13 Bottom Chord Tension provides a limit based on the steel stress, which is used to
Maximum Span based on
define another maximum span limit.
Moment Capacity of Top Chord In accordance with AS 4100 – 1998 Steel Structures, Steel Elastic Modulus, Es = 200,000 MPa

in compression, Ltc =
3.41 m Clause 7.1 – N*≤ΦAgfy Concrete Elastic Modulus, Ecj = 22,610 MPa
Where Φ = 0.9 Largest reinforcement diameter, db = 6.8 mm
Modular Ratio, n = 8.85
Steel Stress Limit, σsteel = 362.3 MPa
Limit State Capacity, ΦA gf y = 281 kN Distance from Soffit to Top Chord = 221.9 mm
Area of Bottom Chord Steel, Ab = 623.4 mm2
Truss Height, Th =
192 mm Transformed Top Chord Area = 9,838 mm2
Area of Mesh Steel, A m = 447.5 mm2
Distance from Soffit to Bottom Chord = 29.9 mm
Limit State Moment Capacity, M*bt = 53.87 kN.m
Total Area of Bottom Steel = 1,071 mm2
Transformed Bottom Chord Area = 4,891 mm2
Maximum Span based on Moment
Equivalent Axial Force, N* = 387.99 kN
Panel Concrete Area = 187,500 mm2
Capacity of Top Chord in tension, L bt = 3.37 m
Truss Height, Th =
192 mm
Distance to the Neutral Axis, yg = 46.29 mm
Limit state moment
Second Moment of Inertia, Ig = 4.07E+08 mm 4

capacity for Steel Stress, M*pf.s = 74.49 kN.m

Maximum Span based
on Flexural Cracking = 3.96 m

/ 40 / / 41 /
 AUSTRAL PRECAST Austral Deck TECHNICAL GUIDE

5.4.6 Deflection 5.4.7 Maximum Spans Summary 5.4.8 Single Span

The maximum deflection of the panel can be calculated from Top chord compression limit = 3.41 m Variables: 75mm precast, fcmi 20MPa, SL72 mesh, 20 cover, Class 2 finish.
either of the following questions: Top chord tension limit = 3.95 m
For an absolute value of a deflection limit, Bottom chord compression limit = 1.33 m 500 T80/10, 250 spacing

(mm) (mm)
4
∆EI T80/10, 565 spacing
√
jwL Bottom chord tension limit = 3.37 m 450
4 s
500 T110/10, 250spacing
T80/10, 250 spacing
∆ = EI L = j4ws Diagonal lacing compression limit = 5.59 m 400

Slab Thickness
450 T110/10,565
T80/10, 565spacing
spacing
Concrete panel compression limit = 5.13 m 350
T150/10,
T110/10, 250 spacing
Where j4 is a value that varies based on the number of spans 400

Slab Thickness
Concrete tension control limit = 2.23 m 300 T150/10,
T110/10, 565 spacing
and ∆ is the deflection limit. For a span: deflection ratio 350
Flexural cracking limit = 3.96 m 250 T110/12,
T150/10, 250 spacing
limit, T110/12, 565 spacing
300 T150/10,

Total Concrete
3
EI Deflection limit = 3.05 m 200

√
L j4wsL T150/12,
250 T110/12, 250 spacing
= Governing limit = 1.33 m
β EI L = βj4ws 150 T150/12,
T110/12, 565 spacing

Total Concrete
Governing limit, ignoring bottom chord 200
100 T190/12,
T150/12, 250 spacing
Where j4 is a value that varies based on the number of spans compression and flexural cracking = 3.05 m 150 T150/12, 565 spacing
50
and β is the span : deflection ration limit. 100 T190/12, 250 spacing
0
50 0 0.5 1 1.5 2 2.5 3 3.5
When choosing the maximum allowable span, the bottom
As the precast slab in assumed to be cracked for deflection 0
chord compression limit may be ignored in some situations. Maximum Distance between Supports (m)
calculation, only the steel truss members are used for the 0 0.5 1 1.5 2 2.5 3 3.5
The bottom chord compression limit can be ignore if the
values of E and I. Any reinforcing mesh is not treated as
bottom concrete panel is assumed to provide sufficient Maximum Distance between Supports (m)
contributing to deflection control as it is not assumed to be
restraint to prevent buckling. When choosing the maximum Chart 2 – Maximum distance between supports for single span
sufficiently attached to the truss frames.
allowable span, the concrete tension control limit may be
ignored. This limit may be ignored as it is based on the
NO. OF SPANS j4 uniaxial tensile strength of the concrete panel, as opposed to
the flexural tensile strength. As the precast panel is not
1 0.0130 5.4.9 Two Span
typically going to be axially loaded, this is not relevant.
2 0.0092 Variables: 75mm precast, fcmi 20MPa, SL72 mesh, 20 cover, Class 2 finish.
The horizontal loading of the framework (AS 3610 – 1995,
≥3 0.0099
Clause 4.4.5) must also be provided for. This will typically be
a role of the edge form designer.
500 T90/10, 250 spacing
Surface quality class = 2

(mm) (mm)
450 T90/10, 565 spacing
Maximum deflection (absolute) = 3 mm 500 T110/10, 250spacing
T90/10, 250 spacing
400

Slab Thickness
Maximum deflection (ration), ß = 270 450 T110/10, 565spacing
T90/10, 565 spacing
350
Area of tensile steel, A st = 623.4 mm2 T150/10,
T110/10, 250 spacing
400

Slab Thickness
300 T150/10, 565 spacing
T110/10,
Distance of tensile steel, dst = 29.9 mm
350 T110/12,
250 T150/10, 250 spacing
Area of comprehensive steel, A sc = 1,112.2 mm2
300 T110/12,
T150/10, 565 spacing

Total Concrete
Distance to comprehensive steel, dsc = 221.9 mm 200
T150/12,
T110/12, 250 spacing
250
Neutral axis height for 150 T150/12, 565 spacing
T110/12,

Total Concrete
200
steel truss only, dsn =
152.9 mm 100 T190/12,
T150/12, 250 spacing
150 T190/12,
T150/12, 565 spacing
Second moment of inertia 50
for steel truss only, Is = 1.47E+07 mm 4 100 T190/12, 250 spacing
0
T190/12, 565 spacing
Maximum span based 50 0 0.5 1 1.5 2 2.5 3 3.5
on absolute limit, L def.abs = 3.05 m 0
Maximum Distance between Supports (m)
Maximum span based 0 0.5 1 1.5 2 2.5 3 3.5
Chart 3 – Maximum distance between supports for multi span
on ration limit, L def,rat = 4.74 m Maximum Distance between Supports (m)
Maximum span based
on serviceability limits, L def = 3.05 m * The information in the graphs are indicative, should be used as a guide only ** The information in the graphs has been generated in accordance with
and does not replace the need for qualified structural design engineer. Australian Standard™. Formwork for concrete. AS 3610 AS 3610-1995
Formwork for Concrete and AS3610.1-2010 Formwork for concrete – Part 1
Documentation and surface finish

/ 42 / / 43 /
 AUSTRAL PRECAST Austral Deck TECHNICAL GUIDE

6. EXAMPLE MODELS AND CALCULATIONS

6.1 S
 ensitivity Analysis of Two-Way Slabs • 3kPa Live Load and 1.5kPa Superimposed Dead Load (SIDL)
– Example 1 • 250mm Austral Deck slabs with 17% weight reduction
The example below is an example of the changes for a simple • Default values for creep and shrinkage coefficients
two-way slab spanning multiple grids. Three cases for the
example are produced: • 30 year load history for cracked section deflection
calculations
• Case 1: Idealised 2-way stiffness (KMr=KMs=1)
The slab is orientated such that R is Left-Right and S is
• Case 2: 75% two-way stiffness (KMr=1, KMs = 0.75) Up-Down on the page. Reducing KMs effectively reduces Figure 29 – Primary positive moment (about R axis)

• Case 3: 50% two-way stiffness (KMr=1, KMs = 0.50) stiffness about the S direction. This is the equivalent of the
planks orientated in the Up-Down direction. For this example,
The example uses:
there might be 2 plank spans in the up-down direction, but
• 2 x 2 spans of 6.5m between columns 5-6 spans in the Left-Right direction.

• 300 x 300 concrete columns The results indicate the following:

Design Case Idealised 2-way 75% Secondary Stiffness 50% Secondary Stiffness

Mid-span Deflection 31.5 mm 36.1 mm 46.7 mm

Primary +ve Moment 38.1 kNm 41.1 kNm 44.6 kNm

Primary -ve Moment -117 kNm -120 kNm -138 kNm

Secondary +ve Moment 38.1 kNm 37.8 kNm 36.6 kNm

Figure 30 – Primary negative moment (about R axis)
Secondary -ve Moment -120 kNm -104 kNm -101 kNm

Table 9 – Differential stiffness results for Three Austral Deck slabs

As the above example is only 2 x 2 spans, there is only limited Results would also be more pronounced for rectangular grid
options for moment redistribution, but the results still layouts, such as 6m x 8.5m, rather than square grid layouts,
indicate increased deflections up to 50% and redistribution of which do not naturally lend themselves to primary and
secondary moments into primary moments. secondary span directions.

The following screen captures are results on the above

options.

Figure 31 – Secondary positive moment (about S axis)

Figure 28 – Long term (30 year) deflection for 100%, 75% and 50% secondary stiffness
Figure 32 – Secondary negative moment (about S axis)

/ 44 / / 45 /
 AUSTRAL PRECAST Austral Deck TECHNICAL GUIDE

6.2 Worked Calculations 6.2.1 Strip 1 – Vertical Span

Using the example model from section 3.3, some further
worked calculations are taken below. In this case, the
bathroom setdowns are removed for simplicity.
The design loads and slab features are as follows:
The above strip is 230 thick, with 2 equal spans of 6.5. It
carries tributary width of approximately 7.5m, but in practice
this amount is reduced due to the semi-two-way nature of the
slab.
The bending moment diagram for the above slab is as follows:

Design Properties Value

General Loading Residential

Superimposed Dead Load 1.0kPa

Live Load 2.0kPa

Slab Thickness 230mm

Precast Thickness 60mm

Columns 400x400

Shrinkage Restraint 11% (Minimal walls)

Figure 34 – Example Slab

The maximum positive strip bending moment for the design The neutral axis depth, 194mm, is based on the total slab
strip is 110kNm over the 2.5m plank width, or 44.0kNm. depth:

To satisfy this moment, reinforcement of 630mm2/m is d = 230 - 30 (cover) - 6( N12 bar

2
)= 194mm
needed, as follows:
Ast ∙ fsy

(
ØMuo = 0.8 ∙ Ast ∙ fsy ∙ d - )
2 ∙ 0.85 ∙ b ∙ f 'c
Negative moment over the columns is 243kNm/m over 2.5m
width.
630 ∙ 500
= 0.8 ∙ 800 ∙ 500 ∙ (194 -

( )
2 ∙ 0.85 ∙ 1000 ∙ 40
This can be provided with 3450mm2 reinforcing in a similar
way, with a traditional reinforcing layout over 2.5m:
= 47.72kNm > 44.0kNm
ØMuo = 0.8 ∙ Ast ∙ fsy ∙ d -( Ast ∙ fsy
)
2 ∙ 0.85 ∙ b ∙ f 'c
630mm2/m can be supplied as N12 bars at 200mm centres
3350 ∙ 500
(565mm2/m) laid on top of SL92 mesh (287mm2/m), or total
852mm2/m. (
= 0.8∙ 3350 ∙ 500 ∙ 194 - )
2 ∙ 0.85 ∙ 2500 ∙ 40
Figure 33 – Example Slab

= 244.08kNm > 243kNm

Two full design strips will be taken as examples, highlighted 3,350mm2 can be supplied by 17 x N16 bars, or N16 at 150mm
above in Red. centres over 2.5m width.

/ 46 / / 47 /
 AUSTRAL PRECAST Austral Deck TECHNICAL GUIDE

6.2.2 Strip 2 – Horizontal Span In the central portion, the width is 2 x D + Column, 6.2.5 Check on Punching Shear
= 2 x 230mm + 400mm = 860mm.
Similar to Strip 1, the positive moments are 100, 50.9 and Punching shear checks are first completed against the in-situ
65.7kNm in the design strip spans 1 to 3 respectively. Over 860mm, N16-150mm is 1152mm2, which provides portion of the slab.
moment of
We take Span 1 as an isolated plank, and achieve the moments In the case of the central column in the above example, the
ØMuo = 78.5kNm < 84.5kNm.
thus: punching shear forces are:

(
ØMuo = 0.8 ∙ Ast ∙ fsy ∙ d - )
Ast ∙ fsy
2 ∙ 0.85 ∙ b ∙ f 'c
This fails clause 9.1.2.

The designer can choose either to increase the reinforcing in Punching Shear Reactions Value

(
= 0.8 ∙ 1350 ∙ 500 ∙ 194 -
1350 ∙ 500
2 ∙ 0.85 ∙ 2500 ∙ 40 ) this location, or to close the bar centres over the column.
V* 584kN

6.2.4 Check on Secondary Moment Direction
= 102.6kNm > 100kNm Mr* 0.02kNm
The secondary negative moments are not addressed in this
1350mm is provided by N12 at 250mm centres plus SL92
2
Ms* 32.3kN
example, as the reinforcing bars are laid traditionally at the
mesh.
top and 2nd layers.
Ms* 32.3kN
For spans 2 and 3, we use 65.7kNm as the critical moment,
The secondary positive moments, however, can only be
which is achieved with N12 at 300mm centres.
resisted by the SL92 mesh case in the precast plank, plus extra
The negative moment for the horizontal span is 210kNm and bars laid on top of the precast at reduced cover (60mm). First check the in-situ portion (D=160mm, dom=125mm) in
151kNm at the two internal columns. accordance with AS3600:
In this example, the secondary moment is 40.8kNm over
(
ØMuo = 0.8 ∙ Ast ∙ fsy ∙ d - )
Ast ∙ fsy
2∙ 0.85 ∙ b ∙ f 'c
2.5m.
(
f 'cv = 0.17 1 + )2
βh
√f 'c ≤ 0.34 √f 'c (but βh = 1)

The moment capacity in the plank using SL92 mesh
3350 ∙ 500
(
= 0.8 ∙ 3350 ∙ 500 ∙ 180 -
2∙0.85∙2500∙40 ) (287mm2/m) is: f 'cv = 0.34 √f 'c = 2.15MPa

= 228.06kNm > 210kNm (

ØMuo = 0.8 ∙ Ast ∙ fsy ∙ d -
Ast ∙ fsy
)
2 ∙ 0.85 ∙ b∙ f 'c
dom = 125, u = 4 ∙ (400+125) = 2100mm
ØVuo = 0.7 ∙ 125 ∙ 2100 ∙ 2.15 = 395kN < 584kN (fail)
Note the reduced cover d=180mm, for the second layer of
rebar.
= 0.8 ∙ 287 ∙ 2.5 ∙ 500 ∙ 194 -( 287 ∙ 2.5 ∙ 500
2∙0.85∙2500∙40
)
Next try the full depth (D=230mm, dom=195mm):
This moment is resisted by 3,350mm2 or N16 at 150mm = 55.6kNm > 40.8kNm
centres over 2500mm. dom = 195, u = 4 ∙ (400 + 195) = 2380mm
However, there are breaks in the planks every 2.5m.
ØVuo = 0.7 ∙ 1 95 ∙ 2380 ∙ 2.15 = 698kN > 584kN (OK)
6.2.3 Check on Column Strip Width To account for the breaks, “cracker” bars are placed over the
breaks, which have cover of approximately 70mm to the bar Check torsion strip reduction, (a=400+195=595mm)

( )
As all of the above strip runs are considered column strips, u ∙ Mv*
centre (d=230-65-12/2 = 159mm)
check that the strip width allocation is appropriate with ØVu = ØVuo 1.0 +
8V* ∙ a ∙ dom
AS3600. The cracker bars should be N12 at 400mm centres (700mm2

In this case, the bottom reinforcing is suitable (with the

over 2500mm): ØVu = ØVuo

(1.0 + 1.0584+ ∙2380 ∙ 32.3
595 ∙ 195
)
( Ast ∙ fsy
) (1.0 +82380
∙ 584 ∙ 595 ∙1 95 )
column strip being 2500mm wide) but the top reinforcing will ØMuo = 0.8 ∙ Ast ∙ fsy ∙ d - ∙ 32.3 × 10
3
2 ∙ 0.85 ∙ b ∙ f 'c ØVu = 698
fail clause 9.1.2, which states:

In two-way flat slabs, at least 25% of the total of the design (

negative moment in a column-strip and adjacent half
middle-strips shall be resisted by reinforcement or tendons or
both, located in a cross-section of slab centred on the column
and of a width equal to twice the overall depth of the slab or
drop panel plus the width of the column.
For this example, in the horizontal span, the total column
moment requirement is:
= 0.8 ∙ 700 ∙ 500 ∙ 159 -
700 ∙ 500
2 ∙ 0.85 ∙ 2500 ∙ 40 ) ØVu = 698 1.1418 = 611.3kN (OK)
As punching shear fails on the in-situ portion alone, but
= 44kNm > 40.8kNm
passes when including the precast portion, the designer
So cracker bars of N12 at 400mm centres are placed, centred should ensure that the total reinforcing bars in the trusses are
over the plank joints. sufficient to “hang up” the load between the precast and
The cracker bars should be at least one splice-length each side in-situ portions of the slab. If not, then shear studs should be
considered.
of the joint, or approximately 1200-1500mm in total.

(210 + 64 + 64) × 25% = 84.5kNm

/ 48 / / 49 /
 AUSTRAL PRECAST Austral Deck TECHNICAL GUIDE

7. FIRE AND THERMAL RESISTANCE

7.1 F
 ire Resistance Period 7.1.2. Thermal Resistance
Austral Deck, as part of the concrete slab can be designed to
7.1.1. Austral Deck Profile
achieve energy efficiency provisions as specified in The
Any concrete slab must be designed to achieve a fire
National Construction Code Volume Two – Building Code of
resistance period(1) (FRP) for structural adequacy, integrity
Australia (BCA).
and insulation of not less than the required fire resistance
level(2) (FRL) as specified in The National Construction Code The Thermal resistance coefficient “The R- Value” (4) of the
– Building Code of Australia (NCC-BCA). Austral Deck slab is affected by the precast panel thickness,
overall slab thickness, the use of slab voids, the use of other
Chart 4 shows FRP for insulation of various slab thicknesses
insulation materials, flooring and ceiling material.
constructed using Austral Deck. The FRP has been
calculated in accordance with Australian Standards: The National Precast Concrete Association of Australia (5)
Concrete Structures, AS3600-2009, Clause 5.2.1 – “NPCAA” has developed a software to calculate the R Value
Insulation for slabs, and modified taking into account of Austral Deck considering all the above factors. Copy of the
Austral Deck profile – Figure 35 and 36. software can be downloaded via the NPCAA website:
www.nationalprecast.com.au/r_value_calculator/
250mm

7.1.3. Definitions and References

Thickness “mm”
200mm

Minimum Slab
150mm
(1) Fire resistance period (FRP)

100mm
Time, in minutes, for a member to reach the appropriate
failure criterion (i.e., structural adequacy, integrity and/or
50mm
insulation) if tested for fire in accordance with the
appropriate Standard. Source Australian Standards,
30min 60min 90min 120min 180min 240min
Concrete Structures, AS3600-2009, Clause 5.2.5
FRP “minutes”

Chart 4 – Fire Resistance Period(3) for insulation for solid slabs

(2) Fire resistance level (FRL)
constructed using Austral
20 Deck profile. Fire resistance periods for structural adequacy, integrity and

16
insulation, expressed in that order.

60, 75, 90
24
NOTE: Fire resistance levels for structures, parts and
elements of construction are specified by the relevant

10
20 10
authority, e.g., in the Building Code of Australia (BCA).

16
60, 75, 90
Source Australian Standards, Concrete Structures, AS3600-

24
2009, Clause 5.2.4

10
10 (3) Section 5 of AS3600-2009 outlines the requirements for
Figure 35 – Austral Deck side profile. the fire resistance of slabs. It is assumed that the criteria for
integrity is considered to be satisfied if the design meets the
criteria for both insulation and structural adequacy for that
fire resistance period as per clause 5.3.1 of AS3600-2009
Effective thickness
for FRP Calculation
250mm (4) The R-value of a substance is its direct measure of its
resistance to transferring energy or heat; R Values are
Thickness “mm”

200mm
Minimum Slab

expressed using the metric units (m2.K/W). The amount of

150mm

thickness
Min slab
Effective thickness
degrees kelvin temperature difference required to transfer
100mm
for FRP Calculation one watt of energy per one square meter of a substance.
50mm
(5) Published with an approval from NPCAA
Austral Deck

thickness
Min slab
30min 60min 90min 120min 180min 240min

Figure 36 – Effective thickness for FRPFRP “minutes”Austral Deck profile.

calculation

Austral Deck

/ 50 / / 51 /
Effective thickness
for FRP Calculation
 AUSTRAL PRECAST Austral Deck TECHNICAL GUIDE

8. TYPICAL INSTALLATION DETAILS

8.1.2. End Support to External Precast Wall – Option 2

Figure 38

8.1 Typical Wall Connection – End Support

8.1.1. End Support to External Precast Wall – Option 1
8.1.3. End Support to Internal Precast Wall

Figure 37 Figure 39

/ 52 / / 53 /
 20

16
AUSTRAL PRECAST Austral Deck TECHNICAL GUIDE

60, 75, 90
24
10
10

8.2 T
 ypical Wall Connection – Longitudinal Side 8.3.2. Mid Span – Internal Precast Wall Above

8.2.1. Longitude Side to External Precast Wall

Effective thickness
for FRP Calculation

thickness
Min slab
Figure 42

Austral Deck

8.3.3. End Support – Double Wall Connection

8.2.2. Side Joint Details

20

thickness
16

Min slab
60, 75, 90
24

Figure 43
10

10 Austral Deck
Austral Deck side profile. Onsite caulking if
required (by others)
Figure 40 8.4 T
 ypical Beam Configuration

8.4.1. Beam Reinforcement within Slab Thickness

8.3 T
 ypical Wall Connection – Internal Precast Wall and Double Wall
8.3.1. End Support – Internal Precast Wall Under
Effective thickness
for FRP Calculation
thickness
Min slab

Figure 44
Austral Deck

Figure 41

Effective thickness / 54 / / 55 /
for FRP Calculation
(without joint sealant)
 AUSTRAL PRECAST Austral Deck TECHNICAL GUIDE

8.4.2. Precast Beam 8.5 Balcony and Cantilever Arrangement

85.1. Balcony and Cantilever Arrangement

Figure 47

Figure 45

8.5.2. External Precast Wall with Balcony

8.4.3. Band Beam formed by Austral Deck

Figure 48

Figure 46

/ 56 / / 57 /
 AUSTRAL PRECAST Austral Deck TECHNICAL GUIDE

8.6 P
 roposed Propping Arrangement

Austral Deck Precast Shell Beam

Precast Shell Beam

Austral Deck

Span Direction

Figure 49

The propping design is provided and shall be certified by the

supplier of the props. The props will be certified to carry the
defined construction loads.

/ 58 / / 59 /
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